Information injection-pump assembly
ZEXEL
101605-3990
1016053990
KOMATSU
6221711310
6221711310
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Cross reference number
ZEXEL
101605-3990
1016053990
KOMATSU
6221711310
6221711310
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.9
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
83.3
82.3
84.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
14
12.8
15.2
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)RACK LIMIT: RAL
(3)Rack difference between N = N1 and N = N2
----------
K=5 RAL=14+0.2mm N1=950r/min N2=700r/min
----------
----------
K=5 RAL=14+0.2mm N1=950r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=1deg+-5deg b=26deg+-5deg c=32deg+-3deg
----------
----------
a=1deg+-5deg b=26deg+-5deg c=32deg+-3deg
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Storage Procedure
When a generator is in storage for any length of time, moisture condenses in the windings. Minimize the condensation by use of a dry storage space and space heaters. Refer to step 2 belowIf a brush-type generator (SRCR) is to be in storage for a year or more, lift the brushes off the slip ring to prevent damage to the slip ring by chemical action.After Storage
Test the main stator windings with a megohmmeter in the following situations: 1. Before initial startup of generator set.2. Every 3 months* if generator is operating in a humid environment.3. If generator has not been run under load for 3 months* or more.*This is a guideline only. It may be necessary to megger more frequently if environment is extremely humid, salty or if the last megger test was close to 1 megohm.The megohmmeter test is described in Service Manuals SENR2180 or SENR7968. A reading of 1 meghom or less indicates that the winding has absorbed too much moisture.To Remove Moisture
To remove moisture caused by high humidity, use one of the following methods to make the generator dry:1. Energize space heaters in generator if so equipped.2. Put the generator in an oven at a temperature of not more than 85°C (185°F) for four hours.
If an oven is used for drying, use a forced air type rather than a radiant type. Radiant ovens can cause localized overheating.
3. Space heaters of the same type used in marine applications, can be installed on generators. (See the Parts Book.) These heaters heat the windings to remove moisture and should be connected at all times in high humidity conditions whenever the generator is not running.4. Use a canvas enclosure around the generator and heating lamps to increase the temperature. Make an opening in the top for release of moisture.5. Send a low voltage current through the windings to increase the temperature of the windings. Do not exceed 85°C (185°F).If the megohmmeter test reads under 1 megohm after the drying or if it goes below 1 megohm shortly after drying, contact your Caterpillar dealer. The insulation has deteriorated and should be reconditioned.
When a generator is in storage for any length of time, moisture condenses in the windings. Minimize the condensation by use of a dry storage space and space heaters. Refer to step 2 belowIf a brush-type generator (SRCR) is to be in storage for a year or more, lift the brushes off the slip ring to prevent damage to the slip ring by chemical action.After Storage
Test the main stator windings with a megohmmeter in the following situations: 1. Before initial startup of generator set.2. Every 3 months* if generator is operating in a humid environment.3. If generator has not been run under load for 3 months* or more.*This is a guideline only. It may be necessary to megger more frequently if environment is extremely humid, salty or if the last megger test was close to 1 megohm.The megohmmeter test is described in Service Manuals SENR2180 or SENR7968. A reading of 1 meghom or less indicates that the winding has absorbed too much moisture.To Remove Moisture
To remove moisture caused by high humidity, use one of the following methods to make the generator dry:1. Energize space heaters in generator if so equipped.2. Put the generator in an oven at a temperature of not more than 85°C (185°F) for four hours.
If an oven is used for drying, use a forced air type rather than a radiant type. Radiant ovens can cause localized overheating.
3. Space heaters of the same type used in marine applications, can be installed on generators. (See the Parts Book.) These heaters heat the windings to remove moisture and should be connected at all times in high humidity conditions whenever the generator is not running.4. Use a canvas enclosure around the generator and heating lamps to increase the temperature. Make an opening in the top for release of moisture.5. Send a low voltage current through the windings to increase the temperature of the windings. Do not exceed 85°C (185°F).If the megohmmeter test reads under 1 megohm after the drying or if it goes below 1 megohm shortly after drying, contact your Caterpillar dealer. The insulation has deteriorated and should be reconditioned.