101605-3500 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016053500 6136721171


 

Information injection-pump assembly

ZEXEL 101605-3500 1016053500
KOMATSU 6136721171 6136721171
101605-3500 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101605-3500 1016053500
KOMATSU 6136721171 6136721171


Zexel num
Bosch num
Firm num
Name
101605-3500 
 
6136721171  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   9.2
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   48.6 47.6 49.6
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   350 350 350
Average injection quantity mm3/st.   9.5 8.5 10.5
Max. variation between cylinders %   0 -10 10
Fixing the rack   *

Test data Ex:

Governor adjustment

Test data 101605-3500
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=7 N1=1200r/min N2=800r/min N3=1200r/min N4=400r/min
----------

Speed control lever angle

Test data 101605-3500
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(4deg)+-5deg b=(19deg)+-5deg

Stop lever angle

Test data 101605-3500
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at speed = aa and rack position = bb.
----------
aa=0r/min bb=1-0.2mm
----------
a=42.5deg+-5deg b=(55deg)

Timing setting

Test data 101605-3500
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(0deg)




Information:

The problems in this section are problems that do come about and are normally called "low power". These problems are not necessarily more common than engine problems, but they are possible problems which you need to read and check before an engine is disassembled.Read all of the items but make sure the first three are checked completely before making any engine test.Possible Causes/Corrections
Tachometer Error
To check, connect a tachometer of known accuracy to the engine. Run the engine and make a comparison of the readings of the vehicle and test tachometers. If vehicle tachometer is defective, make repairs as necessary or install a new tachometer.Engine Operated At High Altitude
Less oxygen at higher altitudes causes the engine horsepower to go down. There is no effect on the horsepower of the engine for the first 2280 m (7500 ft) above sea level of operation.Brakes Do Not Completely Release
Check the brakes by feeling all the brake drums. If the brakes of a wheel do not completely release, the brake drum for that wheel will be hotter than the brake drums for the other wheels. With the truck lifted with a jack, the wheels must have free rotation when turned by hand.Extra Engine Driven Equipment
Air compressors, hydraulic pumps, alternator, and other engine driven equipment that has damage, or that was not installed correctly, or that is not in correct adjustment, can take more horsepower to drive than expected. If necessary, disconnect the equipment and test the engine.Speedometer Error
A defective speedometer does not give the correct speed or the correct indication of fuel consumption. An indication of low speed can cause the operator to feel that he has a power problem.Speeds Too High
The need for more horsepower is easy to see as the speed of the vehicle is increased. This is especially true if the front of the vehicle has a large surface area. Application personnel can give you the horsepower necessary for different vehicle designs at different speeds.Overload On Vehicle
Application personnel can give you the horsepower needs for different vehicles.High Moving Resistance
Soft ground conditions cause a need for more horsepower. To see if the problem is the engine, test the vehicle on a surface known to be good, or test on a chassis dynamometer.High Wind Resistance
The horsepower needs for a truck can be divided into two parts. Part of the horsepower is used to move the vehicle and part is used to get through the resistance of the wind. The horsepower necessary to get through the resistance of the wind will increase as the vehicle is used at higher speeds. Vehicles with a large front area have a higher wind resistance and take more horsepower than those with a small front area. Some types of trucks, for example those used for the transportation of automobiles and or boats have high wind resistance even if the front area is small. Moving against the wind has the same effect on wind resistance as does higher vehicle speed.Power Loss In Drive Gears
It is possible for a

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