Information injection-pump assembly
ZEXEL
101692-3580
1016923580
KOMATSU
6207711940
6207711940
Rating:
Service parts 101692-3580 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
19.6(200)
15.
NOZZLE SET
Cross reference number
ZEXEL
101692-3580
1016923580
KOMATSU
6207711940
6207711940
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
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
Rack position
Point A R=A
Point A R=A
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
10
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
35.4
34.4
36.4
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
10.9+-0.
5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
12.5
11.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK CAP: R1
(3)Rack difference between N = N1 and N = N2
(4)Rack difference between N = N3 and N = N4
----------
K=15 R1=(17.5)mm N1=1200r/min N2=800r/min N3=1200r/min N4=400r/min
----------
----------
K=15 R1=(17.5)mm N1=1200r/min N2=800r/min N3=1200r/min N4=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=20deg+-5deg b=27deg+-5deg
----------
----------
a=20deg+-5deg b=27deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)-
(5)-
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
Literature Information
This Manual contains safety, operation instructions, lubrication and maintenance information. Read - study - and keep it with the truck/vehicle literature and engine information.Some photographs or illustrations in this Manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes.Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this Manual.Whenever a question arises regarding your engine, or this Manual, please consult Caterpillar for the latest available information.Safety
The safety section lists basic safety precautions. In addition, this sectio identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.Operation
The operation section is a reference for operators and photographs and illustrations guide the operator through correct procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of gauges, protection devices, engine controls and lifting and storage information.Maintenance
The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by Preventive Maintenance servicing intervals. Items in the Maintenance Schedule are referenced to detailed instructions that follow. Maintenance Intervals are listed for "ideal" operating conditions of vehicles on paved roads in good condition and at average travel speeds. Maintenance Intervals must be reduced when operating in adverse conditions. Refer to the Maintenance Reduction Factors in the Maintenance Section of this Manual for information.Recommended service should always be performed at the interval that occurs first. More frequent maintenance checks than specified in the Maintenance Schedule will be necessary when operating under very severe, dusty or freezing cold operating conditions. Refer to the Severe Service Application topics in this Manual for the information.Overhaul
Major engine repair such as overhaul is not covered in this Manual except for the overhaul interval and the maintenance items in that interval. Major repairs are best left to the trained personnel of Caterpillar. Caterpillar offers a variety of options regarding overhaul programs. If you experience a major engine failure which necessitates removal of the engine from the chassis, there are numerous after failure overhaul options available.
This Manual contains safety, operation instructions, lubrication and maintenance information. Read - study - and keep it with the truck/vehicle literature and engine information.Some photographs or illustrations in this Manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes.Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this Manual.Whenever a question arises regarding your engine, or this Manual, please consult Caterpillar for the latest available information.Safety
The safety section lists basic safety precautions. In addition, this sectio identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.Operation
The operation section is a reference for operators and photographs and illustrations guide the operator through correct procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of gauges, protection devices, engine controls and lifting and storage information.Maintenance
The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by Preventive Maintenance servicing intervals. Items in the Maintenance Schedule are referenced to detailed instructions that follow. Maintenance Intervals are listed for "ideal" operating conditions of vehicles on paved roads in good condition and at average travel speeds. Maintenance Intervals must be reduced when operating in adverse conditions. Refer to the Maintenance Reduction Factors in the Maintenance Section of this Manual for information.Recommended service should always be performed at the interval that occurs first. More frequent maintenance checks than specified in the Maintenance Schedule will be necessary when operating under very severe, dusty or freezing cold operating conditions. Refer to the Severe Service Application topics in this Manual for the information.Overhaul
Major engine repair such as overhaul is not covered in this Manual except for the overhaul interval and the maintenance items in that interval. Major repairs are best left to the trained personnel of Caterpillar. Caterpillar offers a variety of options regarding overhaul programs. If you experience a major engine failure which necessitates removal of the engine from the chassis, there are numerous after failure overhaul options available.