101692-3710 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016923710 6207711190

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101692-3710 1016923710

KOMATSU 6207711190 6207711190

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Cross reference number

ZEXEL 101692-3710 1016923710

KOMATSU 6207711190 6207711190

Zexel num

Bosch num

Firm num

Name

101692-3710

6207711190 KOMATSU

INJECTION-PUMP ASSEMBLY
S6D95L * 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 3.6 3.55 3.65

Rack position
Point A R=A

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

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 52.8 51.8 53.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.3+-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.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K
----------
K=8
----------

Speed control lever angle

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

----------
a=3deg+-5deg b=27deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
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

Information:

Alternator and Fan Drive Belts
Inspect/Adjust/Replace
Your engine will be equipped with a water pump belt and a pair of belts for the fan drive and alternator. Inspect the condition and adjustment of alternator and fan drive belts. Inspect all drive belts and replace if they show any signs of wear.Check and adjust the belt tension to minimize belt slippage. If belts are too loose, they vibrate enough to cause unnecessary wear on the belts and pulleys. If belts are too tight, unnecessary stresses are placed upon the pulley bearings and belts which might shorten the life of both.To Adjust Drive Belt
The alternator is used for tension adjustment. Correctly adjusted belts will deflect approximately 9 to 15 mm (3/8 to 5/8 inch). If new belt(s) are installed, check belt adjustment again after 30 minutes of operation.To adjust the belt tension, loosen the alternator bolts and slide the alternator in the desired direction to increase or decrease the belt tension. 1. To adjust the alternator drive belt, loosen mounting bolt (1) and the adjusting bracket bolt (2).2. Move the alternator in or out as required to obtain the correct adjustment. Tighten the bolts (1) and (2). Do not overtighten.3. If new belts are installed, check belt adjustment again after 30 minutes of engine operation.To Adjust Water Pump Belt
1. To adjust the water pump drive belt, loosen mounting bolt and bracket bolt.2. Move water pump idler pulley in or out as required to obtain the correct adjustment.3. To make the correct adjustment, use the square hole in the mounting bracket or bolt to apply tension.4. Tighten bolts. Do not overtighten. The water pump belt is not used to drive any other accessories. Excessive tightening can damage the water pump bearings or shaft.5. If a new belt is installed, check the belt adjustment again after 30 minutes of engine operation at rated speed.Fan Drive Bearing
Lubricate
Lubricate one fitting with Caterpillar 2S3230 SPG grease. Refer to the Lubrication Specifications section in this Manual for the proper lubricating grease to be used.Inspect the fan drive pulley assembly. It should be difficult to detect movement of the shaft in the bearing. If the shaft is loose in the bearings, an inspection of the internal components should be made.The bearing end play should be 0.03 to 0.23 mm (.001 to .009 inch). The radial play should be no greater than 0.13 mm (.005 inch). Fan Clutch-For emergency operation or electrical override, use one M6 x 1 cap screw inserted in fan spider clearance holes to allow continuous operation of fan. Have fan clutch repaired at next stop.
Do NOT operate engine with this condition for long periods of time because an engine over cooling problem (low operating temperatures) will cause sludge formation and excessive carbon build-up on critical engine components.
If the assembly should require disassembly, refer to the Service Manual for the procedure.Battery
Check the following at least every 6 months, and more often if conditions require.Tighten Terminals
* Clean the top of the batteries with a clean cloth. Loosen and