Information injection-pump assembly
ZEXEL
101692-3940
1016923940
KOMATSU
6207711611
6207711611
Rating:
Service parts 101692-3940 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6207-11-3100
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101692-3940
1016923940
KOMATSU
6207711611
6207711611
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
3.2
3.15
3.25
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
7.9
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
56
55
57
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.9+-0.5
Pump speed
r/min
240
240
240
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.
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 difference between N = N1 and N = N2
----------
K=10 N1=1500r/min N2=800r/min
----------
----------
K=10 N1=1500r/min N2=800r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=46deg+-5deg b=26deg+-5deg
----------
----------
a=46deg+-5deg b=26deg+-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
0000001501 Q ADJUSTMENT PIPING
Fuel hose piping outline
Tester fuel pipe A
(B) branch piping
Fuel hose C
(D) Fuel inlet
1. Because the pump gallery is divided into two, be careful of the fuel piping at adjustment.
(1)Connect the fuel inlet hose to port (C), and connect the branch pipe.
(2)Connect the tester fuel piping to the branch pipe.
----------
----------
----------
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)
Information:
For all marine transmission lubrication and maintenance activities, refer to your marine transmission or vessel OEM literature.Use fuel consumption, service hours, or calendar time, whichever occurs first, to determine maintenance intervals. Experience has shown that maintenance intervals are most accurately scheduled on the basis of fuel consumed rather than service hours.Daily
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Air Cleaner - Check service indicator/Service air cleaner when needed Air Starter (If Equipped) - Check lubricator oil level Clutch (If Equipped) - Check/Adjust/Lubricate Marine Transmission - Check oil levelEvery 3800 L (1000 gal) of Fuel or 50 Hours
Zinc Rods - Inspect/ReplaceEvery 19,000 L (5,000 gal) Of Fuel Or 250 Hours or Yearly
Fuel System - Clean primary fuel filter (if equipped)/Replace final fuel filter Fuel Tank - Drain water and sediment Cooling System (Conventional HD Coolant Only) - Test for SCA concentration OR obtain Level I coolant analysis/Add SCA if necessary Air Cleaner - Clean/Replace air filter elements Belts - Check/Adjust/Replace Hoses and Clamps - Inspect/Replace Batteries - Clean/Check (if required)First 38,000 L (10,000 gal) of Fuel or 500 Hours
Valve Lash - Check/Adjust (at the first oil change interval)Every 38,000 L (10,000 gal) of Fuel or 500 Hours
Scheduled Oil Sampling (S O S) - Obtain Sample and analysis Engine Crankcase - Replace oil and filter(s) Crankcase Breathers - CleanEvery 76,000 L (20,000 gal) Of Fuel Or 1000 Hours
Engine Protection Devices - Inspect/Check Magnetic Pickup - Inspect/AdjustEvery 227,500 L (60,000 gal) Of Fuel Or 3000 Hours
Water Temperature Regulators (Thermostats) - Replace Cooling System (Extended Life Coolant Only) - Add Extender1 Cooling System (Conventional HD Coolant Only) - Drain/Clean/Replace coolant Engine Mounts - Inspect Crankshaft Vibration Damper - Inspect Valve Lash, Valve Rotators - Check/Adjust Fuel Ratio Control, Set Point, and Low Idle - Check/Adjust PAR Analysis - ObtainEvery 379,000 L (100,000 gal) Of Fuel Or 5000 Hours
Fuel Injection Nozzles - Test/Exchange Jacket Water Pump - Inspect/Rebuild or Exchange Raw/Sea Water Pump - Inspect/Rebuild or Exchange Alternator - Inspect/Rebuild or Exchange Starting Motor - Inspect/Rebuild or Exchange Air Compressor (If Equipped) - Inspect/Rebuild or Exchange Turbocharger - Clean/Inspect/CheckEvery 6000 Hours Or Four Years
Cooling System (Extended Life Coolant Only) - Drain/Flush/Replace CoolantOverhaul
Overhaul Considerations1If a commercial HD coolant/antifreeze meeting ASTM D4985 specifications is used, or if a mixture of commercial SCA and water is used, this maintenance should be performed at a maximum of One Year.
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Air Cleaner - Check service indicator/Service air cleaner when needed Air Starter (If Equipped) - Check lubricator oil level Clutch (If Equipped) - Check/Adjust/Lubricate Marine Transmission - Check oil levelEvery 3800 L (1000 gal) of Fuel or 50 Hours
Zinc Rods - Inspect/ReplaceEvery 19,000 L (5,000 gal) Of Fuel Or 250 Hours or Yearly
Fuel System - Clean primary fuel filter (if equipped)/Replace final fuel filter Fuel Tank - Drain water and sediment Cooling System (Conventional HD Coolant Only) - Test for SCA concentration OR obtain Level I coolant analysis/Add SCA if necessary Air Cleaner - Clean/Replace air filter elements Belts - Check/Adjust/Replace Hoses and Clamps - Inspect/Replace Batteries - Clean/Check (if required)First 38,000 L (10,000 gal) of Fuel or 500 Hours
Valve Lash - Check/Adjust (at the first oil change interval)Every 38,000 L (10,000 gal) of Fuel or 500 Hours
Scheduled Oil Sampling (S O S) - Obtain Sample and analysis Engine Crankcase - Replace oil and filter(s) Crankcase Breathers - CleanEvery 76,000 L (20,000 gal) Of Fuel Or 1000 Hours
Engine Protection Devices - Inspect/Check Magnetic Pickup - Inspect/AdjustEvery 227,500 L (60,000 gal) Of Fuel Or 3000 Hours
Water Temperature Regulators (Thermostats) - Replace Cooling System (Extended Life Coolant Only) - Add Extender1 Cooling System (Conventional HD Coolant Only) - Drain/Clean/Replace coolant Engine Mounts - Inspect Crankshaft Vibration Damper - Inspect Valve Lash, Valve Rotators - Check/Adjust Fuel Ratio Control, Set Point, and Low Idle - Check/Adjust PAR Analysis - ObtainEvery 379,000 L (100,000 gal) Of Fuel Or 5000 Hours
Fuel Injection Nozzles - Test/Exchange Jacket Water Pump - Inspect/Rebuild or Exchange Raw/Sea Water Pump - Inspect/Rebuild or Exchange Alternator - Inspect/Rebuild or Exchange Starting Motor - Inspect/Rebuild or Exchange Air Compressor (If Equipped) - Inspect/Rebuild or Exchange Turbocharger - Clean/Inspect/CheckEvery 6000 Hours Or Four Years
Cooling System (Extended Life Coolant Only) - Drain/Flush/Replace CoolantOverhaul
Overhaul Considerations1If a commercial HD coolant/antifreeze meeting ASTM D4985 specifications is used, or if a mixture of commercial SCA and water is used, this maintenance should be performed at a maximum of One Year.