101605-3760 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016053760 6137721171

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101605-3760 1016053760

KOMATSU 6137721171 6137721171

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Cross reference number

ZEXEL 101605-3760 1016053760

KOMATSU 6137721171 6137721171

Zexel num

Bosch num

Firm num

Name

101605-3760
101605-3820

6137721171 KOMATSU

INJECTION-PUMP ASSEMBLY
S6D105 * 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 10.5

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 70.5 69.5 71.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 49.3 49.3

Boost pressure mmHg 370 370

Injection quantity adjustment_02

Adjusting point B

Rack position 8+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 9.6 8.1 11.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 10.4

Boost pressure kPa 16 13.3 18.7

Boost pressure mmHg 120 100 140

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 11.5

Boost pressure kPa 36 29.3 42.7

Boost pressure mmHg 270 220 320

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Set idle sub-spring (3)Main spring setting (4)Boost compensator stroke (5)Rack difference between N = N1 and N = N2 (6)Rack difference between N = N3 and N = N4 (7)Rack difference between N = N5 and N = N6.
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K=15 N1=1150r/min N2=1000r/min N3=1150r/min N4=800r/min N5=1150r/min N6=350r/min
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Speed control lever angle

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

----------
a=10deg+-5deg b=24deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)Stopper bolt setting
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aa=0r/min bb=1-0.2mm
----------
a=42.5deg+-5deg b=(55deg)

Timing setting

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

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

Information:

Start By:a. remove flywheel The crankshaft rear seal and wear sleeve come as a set and must be installed as a set. If a replacement of the seal is to be made, a replacement of the wear sleeve must also be made. 1. Make at least three holes in seal (1) with a hammer and a sharp punch.2. Use tool (A) to remove seal (1). 3. Install tool (C) in the seal bore.4. Install tool (B) between tool (C) and wear sleeve (2). Turn tool (B) until the tool makes a dent (crease) in wear sleeve (2). Do this in three or more places until the wear sleeve is loose.5. Remove tools (B) and (C), and remove wear sleeve (2) from the crankshaft.Install Crankshaft Rear Seal And Wear Sleeve
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instruction, Form No. SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
1. Install the rear crankshaft seal and wear sleeve with tooling (D). Use the procedures which follow: a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the crankshaft outside diameter before the wear sleeve is installed on the crankshaft. Do not let any Quick Cure Primer or Retaining Compound get on the lip of the seal.b. Install locator (3) and the bolts on crankshaft (4).c. The seal and wear sleeve must be installed dry. Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the rear seal group for an engine is different from the front seal group. If a seal group is installed on the wrong side of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
d. Put wear sleeve (2) and seal (7) as a unit in position on locator (3).e. Put installer (5) in position on locator (3).f. Put clean engine oil on the face of nut (6) and its contact area on installer (5). Install nut (6) on locator (3).g. Tighten nut (6) until installer (5) makes contact with locator (3).h. Remove tooling (D) from the crankshaft seal and wear sleeve. Tooling (D) will install the seal and wear sleeve to the correct depth on the crankshaft.End By:a. install flywheel