101605-3910 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016053910 6138721481

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101605-3910 1016053910

KOMATSU 6138721481 6138721481

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Cross reference number

ZEXEL 101605-3910 1016053910

KOMATSU 6138721481 6138721481

Zexel num

Bosch num

Firm num

Name

101605-3910

6138721481 KOMATSU

INJECTION-PUMP ASSEMBLY
S6D110 * 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

Overflow valve 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 4 3.95 4.05

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 11

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 113.3 112.3 114.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 8+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 13.5 13.5 13.5

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.7+-0.5

Pump speed r/min 775 775 775

Average injection quantity mm3/st. 20 18.8 21.2

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)Idle sub spring setting: L1. (3)Rack difference between N = N1 and N = N2
----------
K=15 L1=7-0.5mm N1=750r/min N2=450r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Stopper bolt setting (3)Pump speed = bb
----------
aa=900r/min bb=750r/min
----------
a=24deg+-5deg b=6deg+-5deg c=6deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=26.5deg+-5deg b=53deg+-5deg

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:

Altitude Operation
The fuel system settings and altitude limits are stamped on the engine information plate. When an engine is moved to a higher altitude, these settings must be changed by your Caterpillar dealer in order to prevent damaging the turbocharger, and to provide maximum engine efficiency. If the engine is moved to a lower altitude than that which is stamped on the engine information plate, the engine can be operated safely; however, it will deliver less than rated horsepower, and the fuel settings should be changed by your Caterpillar dealer to obtain rated horsepower.Stopping
1. Flywheel clutch operation: Quickly pull the clutch lever to the released position. For electric set operation, see the GENERATOR SET OPERATION instructions. For Woodward Governor operation, see the topic, WOODWARD GOVERNORS, Stopping the Engine. 2. Reduce engine speed to half speed. Run for 5 minutes to cool engine.3. Reduce engine speed to low idle.4. Observe the crankcase oil level while the engine is idling. Maintain the oil level between the ADD and FULL marks on the side of the dipstick stamped, CHECK WITH ENGINE RUNNING. See the LUBRICATION AND MAINTENANCE SECTION.5. Stop the engine. After Stopping Checks And Procedures
1. Fill the fuel tank. See the LUBRICATION AND MAINTENANCE SECTION: Fuel Tank Maintenance.2. Drain the raw water system if below freezing temperatures are expected; see: Draining Raw Water System.3. If below freezing temperatures are expected, allow the engine jacket water expansion tank to cool; then check the coolant for proper antifreeze protection. Add permanent-type antifreeze, if required.4. Repair any leaks, make major adjustments, tighten loose bolts, etc.5. Observe the Service Meter reading. Perform the periodic maintenance as instructed in the LUBRICATION AND MAINTENANCE CHART.
SERVICE METER