Information injection-pump assembly
ZEXEL
103662-2812
1036622812
KOMATSU
6162731371
6162731371
Rating:
Cross reference number
ZEXEL
103662-2812
1036622812
KOMATSU
6162731371
6162731371
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1500
Outer diameter - inner diameter - length (mm) mm 8-4-1500
Overflow valve
133424-0420
Overflow valve opening pressure
kPa
206
172
240
Overflow valve opening pressure
kgf/cm2
2.1
1.75
2.45
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.8
3.75
3.85
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
15.3
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
483
478
488
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Boost pressure
kPa
61.3
61.3
Boost pressure
mmHg
460
460
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.3+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
51.7
46.7
56.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
13.9
Boost pressure
kPa
21.3
18.6
24
Boost pressure
mmHg
160
140
180
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
15.9
Boost pressure
kPa
48
41.3
54.7
Boost pressure
mmHg
360
310
410
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)Boost compensator stroke: BCL
(4)Rack difference between N = N1 and N = N2
----------
K=(15)mm RAL=17+0.2mm BCL=2+-0.1mm N1=1050r/min N2=650r/min
----------
----------
K=(15)mm RAL=17+0.2mm BCL=2+-0.1mm N1=1050r/min N2=650r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=8deg+-5deg b=(35deg)+-5deg
----------
----------
a=8deg+-5deg b=(35deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Clearance between stopper bolt and lever must be aa.
(2)At pump speed bb and rack position cc, set the stopper bolt.
----------
aa=2+1mm bb=100r/min cc=5mm
----------
a=16deg+-5deg b=40deg+-5deg
----------
aa=2+1mm bb=100r/min cc=5mm
----------
a=16deg+-5deg b=40deg+-5deg
Information:
Typical Example1. Remove bolts (1) and cover (2). Remove bolts (3) and cover (4).
Typical Example2. Remove bolts (5) and adapter (6). Be sure that gear stays in place. Remove bolts (7) and cover (8). Keep gear in place.
Typical Example3. Remove gears (9) and crankshaft gear (10). Remove bolts (11) and idler gear (12) with retainer. Remove bolts (13) and idler gear (14) with retainer.
Typical Example4. Secure strap and a hoist to housing (15). Remove hose assembly (16) and small bolts (17) and large bolts (18). 5. Remove bolts (19) that connect housing to oil pan (20). Remove housing from cylinder block. The weight of housing is approximately 105 kg (230 lb). 6. Check O-ring seal (21) and bearing (22) on adapter and replace if necessary. 7. Check bearing (23) and O-ring seal (24) on cover and replace if necessary. 8. Remove retainer (25) from gear (9) and check bearings (26) and replace if necessary. The following steps are for the installation of the flywheel housing.9. Thoroughly clean the contact surfaces of the cylinder block and flywheel housing. Install a new gasket between the flywheel housing and the cylinder clock.10. Secure strap and a hoist to the flywheel housing, put flywheel housing in position on the cylinder block. 11. Install the bolts that hold the flywheel housing to the cylinder block. Tighten bolts 1 thru 22 in number sequence to a torque of 40 10 N m (30 7 lb ft). Tighten bolts 1 thru 9 in number sequence again to a torque of 135 20 N m (100 15 lb ft). Tighten bolts 10 thru 22 in number sequence again to a torque of 55 10 N m (40 7 lb ft).12. Install bolts that connect housing to oil pan.13. Cut flywheel housing gasket off even with the cylinder block surface. Remove excess sealant.End By:a. install crankshaft rear seal and wear sleeveb. install starting motor