Information injection-pump assembly
ZEXEL
101695-3160
1016953160
KOMATSU
6207711421
6207711421
Rating:
Service parts 101695-3160 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6207-11-3102
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101695-3160
1016953160
KOMATSU
6207711421
6207711421
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
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
11.7
Pump speed
r/min
750
750
750
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
9.9+-0.5
Pump speed
r/min
400
400
400
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)Idle sub spring setting: L1.
----------
K=13 R1=(17.5)mm N1=750r/min N2=400r/min L1=6.5-0.5mm
----------
----------
K=13 R1=(17.5)mm N1=750r/min N2=400r/min L1=6.5-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Pump speed = aa
(2)Stopper bolt setting
(3)Pump speed = bb
----------
aa=900r/min bb=750r/min
----------
a=2deg+-5deg b=24deg+-5deg c=7deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=2deg+-5deg b=24deg+-5deg c=7deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
(2)At hole above left hand side R = aa
----------
aa=27mm
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
aa=27mm
----------
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)-
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
----------
----------
a=59deg36min+-3deg b=0deg24min+-30min
Information:
The diagnostic lamp, on the truck dashboard, can be used to communicate status or operation problems of the electronic control system.Trucks With Cruise
The dash mounted cruise switches are used to interrogate the ECM for system status. With the cruise switch in the "off" position, hold the set/resume switch in the resume position until "check engine" light begins to flash. The sequence of flashes represents the system diagnostic message. The first sequence of flashes adds up to the first digit of the fault code. After a one second pause, a second sequence of flashes will occur which represents the second digit of the fault code. Any additional fault codes will follow, after a pause, and will be displayed in the same manner.Trucks Without Cruise
If cruise control switches are not installed or if their configuration (such as a GM type switch) does not permit their usage for checking diagnostic codes, then a push button momentary ON switch should be installed between Pin 3 of the vehicle connector P7 and engine ground.Faults With Throttle Response
The vehicle should be driven to a dealer for service ONLY if the engine oil pressure gauge indicates normal engine oil pressure and engine fuel pressure is within the normal range.Faults Without Throttle Response
If the check engine light is on and the engine does not respond to changes in throttle position, the vehicle should be driven to a dealer ONLY if the oil pressure gauge indicates normal engine oil pressure and engine fuel pressure is within the normal range.If equipped, turn on the cruise on/off switch and operate the vehicle using the set/resume cruise control switch to raise and lower the engine rpm.The cruise control mode is operational from 0 km/h (mph) up to the vehicle speed limit (VSL) when the 3406B (PEEC III) control unit does not respond to changes in throttle position. Maximum engine rpm will be the programmed engine rpm at the vehicle speed limit (VSL). Cruise control must be reselected after each gear change.
The dash mounted cruise switches are used to interrogate the ECM for system status. With the cruise switch in the "off" position, hold the set/resume switch in the resume position until "check engine" light begins to flash. The sequence of flashes represents the system diagnostic message. The first sequence of flashes adds up to the first digit of the fault code. After a one second pause, a second sequence of flashes will occur which represents the second digit of the fault code. Any additional fault codes will follow, after a pause, and will be displayed in the same manner.Trucks Without Cruise
If cruise control switches are not installed or if their configuration (such as a GM type switch) does not permit their usage for checking diagnostic codes, then a push button momentary ON switch should be installed between Pin 3 of the vehicle connector P7 and engine ground.Faults With Throttle Response
The vehicle should be driven to a dealer for service ONLY if the engine oil pressure gauge indicates normal engine oil pressure and engine fuel pressure is within the normal range.Faults Without Throttle Response
If the check engine light is on and the engine does not respond to changes in throttle position, the vehicle should be driven to a dealer ONLY if the oil pressure gauge indicates normal engine oil pressure and engine fuel pressure is within the normal range.If equipped, turn on the cruise on/off switch and operate the vehicle using the set/resume cruise control switch to raise and lower the engine rpm.The cruise control mode is operational from 0 km/h (mph) up to the vehicle speed limit (VSL) when the 3406B (PEEC III) control unit does not respond to changes in throttle position. Maximum engine rpm will be the programmed engine rpm at the vehicle speed limit (VSL). Cruise control must be reselected after each gear change.