101602-3530 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016023530 6136721510

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-3530 1016023530

KOMATSU 6136721510 6136721510

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Cross reference number

ZEXEL 101602-3530 1016023530

KOMATSU 6136721510 6136721510

Zexel num

Bosch num

Firm num

Name

101602-3530

6136721510 KOMATSU

INJECTION-PUMP ASSEMBLY
6D105 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 8.5

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 40 39 41

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 10 8.5 11.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Rack difference between N = N1 and N = N2 (3)Rack difference between N = N3 and N = N4
----------
K=10 N1=1150r/min N2=800r/min N3=1150r/min N4=500r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=9deg+-5deg b=20deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=27deg+-5deg b=53deg+-5deg

Information:

Table 1
Revision Summary of Changes
01 Added prefix S/N:8811-8299 Description Of Change: The new Diesel Exhaust Fluid (DEF) control unit software now used, has been released to improve the priming performance of DEF pumps in cold environments.Adaptable To:
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.The new and former part numbers are listed in Table 2.
Table 2
Required Parts
Qty Dosing Control Unit (DCU) Dosing Control Unit (DCU) Voltage New Part Number Part Name Former Part Numbers(1)
1 Restriction on Hazardous Substance (RoHS) (DCU) 24V 593-7031 Engine Software 567-5763
1 Restriction on Hazardous Substance (RoHS) (DCU) 12V 593-7030 Engine Software 567-5761
1 Non-Restriction on Hazardous Substance (RoHS) (DCU) 24V 593-7033 Engine Software 539-3577
1 Non-Restriction on Hazardous Substance (RoHS) (DCU) 12V 593-7032 Engine Software 539-3576
(1) The former part number listed is for reference only and may differ.The new software is available in the form of a flash file through the Caterpillar Service Information System (SIS). A newer part number may be available. SIS web only displays the latest available flash file.