101605-3940 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016053940 6209711350


 

Information injection-pump assembly

ZEXEL 101605-3940 1016053940
KOMATSU 6209711350 6209711350
101605-3940 INJECTION-PUMP ASSEMBLY
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Service parts 101605-3940 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-3900
3. GOVERNOR 105400-5081
4. SUPPLY PUMP 105220-5420
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105662-1190
7. COUPLING PLATE 156637-8520
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-4551
11. Nozzle and Holder 6207-11-3200
12. Open Pre:MPa(Kqf/cm2) 24.5{250}
13. NOZZLE-HOLDER 105048-3300
14. NOZZLE 105017-0430
15. NOZZLE SET

Include in #1:

101605-3940 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101605-3940 1016053940
KOMATSU 6209711350 6209711350


Zexel num
Bosch num
Firm num
Name
101605-3940 
101605-3941 
 
6209711350  KOMATSU
INJECTION-PUMP ASSEMBLY
6M91A * K 14BE PE6A PE

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   3.6 3.55 3.65
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   11.1
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   92.6 91.6 93.6
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   9.1+-0.5
Pump speed r/min   265 265 265
Average injection quantity mm3/st.   8 7 9
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 

Test data Ex:

Governor adjustment

Test data 101605-3940
N:Pump speed R:Rack position (mm) (1)Target notch: K
----------
K=5
----------

Speed control lever angle

Test data 101605-3940
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=50deg+-5deg b=25deg+-5deg

Stop lever angle

Test data 101605-3940
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101605-3940
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)




Information:

Lubrication Specifications
Crankcase Lubricating Oils
Use oils which meet Engine Service Classification CD (MIL-L-2104D) or CD/TO-2. These are additive-type oils that have been approved for use in Caterpillar Diesel Engines.Consult the "EMA Lubricating Oils Data Book," Form SEBU5939, for a listing of CD oil brands.The proper SAE grade of oil to select is determined by the ambient temperature at which the engine is started and the maximum ambient temperature in which the engine will be operating. See chart for recommended viscosity and temperature range.To determine if the oil in the crankcase will flow in cold weather, remove the oil dipstick before starting. If the oil will flow off, the oil is fluid enough to circulate properly.Lubricating Grease
Use Multipurpose-type Grease (MPGM) which contains 3-5% molybdenum disulfide conforming to MIL-M-7866, and a suitable corrosion inhibitor. NLGI No. 2 Grade is suitable for most temperatures. Use NLGI No. 0 or No. 1 Grade for extremely low temperatures.Recommended Lubricant Viscosities
Air Starting Motor Oiler: Use SAE 10W in all temperatures.Flywheel Clutch Bearing Reservoir: Use SAE 30 in all temperatures. Fuel Specifications
No. 2 fuel oil and No. 2D diesel fuel are recommended for use in Caterpillar Diesel Engines. In extreme cold temperatures use No. 1 fuel oil or No. 1D diesel fuel.In selecting a fuel, note that distillate fuels are especially desirable because the fuel is heated to a vaporous state and condensed, thus eliminating all sediment and residue.There is considerable variation in the composition of fuels distributed under the No. 2 grade classifications. For desirable engine service it is most important to give special attention to cetane no., water and sediment, pour point, cloud point and sulphur content. USE THE LOWEST PRICE DISTILLATE FUEL WHICH MEETS THE FOLLOWING REQUIREMENTS.Water and Sediment 0.1% sedimentCetane No. (PC Engine) 35 minimum(DI Engine) 40 minimumPour Point 10°F (6°C) below ambient temperatureCloud Point No higher than ambient temperatureSulphur Content* Adjust oil change periodGravity 32-40 A.P.I. at 60°F (15.6°C)*See the topic SULPHUR CONTENT. Cetane No: This is an indication of a fuel's ignition quality and should not be less than 35 for the PC engine and 40 for the DI engine. For high altitude operation or cold weather starting, a higher cetane number is required. Water and Sediment: A good clean fuel will contain no more than 0.1% sediment and water. Dirty fuels lead to early filter plugging and in addition can result in the formation of gums and resins reducing filter and engine life. Pour Point: The pour point of the fuel has no effect on engine performance, as long as the fuel is fluid enough to flow from the fuel tank to the engine. The pour point of the fuel should be at least 10°F (6°C) below the lowest atmospheric temperature at which the engine must start and operate. In extremely cold temperatures it may be necessary to use No. 1 fuel oil or No. 1D diesel fuel. Cloud Point: Cloud point is the temperature at which wax crystals become visible and is generally above the pour point of

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