Information injection-pump assembly
ZEXEL
103662-3351
1036623351
KOMATSU
6162741310
6162741310
Rating:
Service parts 103662-3351 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6162-14-7601
12.
Open Pre:MPa(Kqf/cm2)
29.4{300}
15.
NOZZLE SET
Cross reference number
ZEXEL
103662-3351
1036623351
KOMATSU
6162741310
6162741310
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
131425-1620
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
RED3 control unit part number
407910-2
470
RED3 rack sensor specifications
mm
15
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
3.2
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
Rack position
(13.2)
Vist
V
1.36
1.36
1.36
Pump speed
r/min
865
865
865
Average injection quantity
mm3/st.
627
622
632
Max. variation between cylinders
%
0
-4
4
Basic
*
Injection quantity adjustment_02
Rack position
(6.1)
Vist
V
2.8
2.7
2.9
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
49
44
54
Max. variation between cylinders
%
0
-14
14
Test data Ex:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=16mm bb=1mm
----------
a=29deg+-5deg b=39deg+-5deg
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aa=16mm bb=1mm
----------
a=29deg+-5deg b=39deg+-5deg
0000000901
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
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a=(70deg)
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----------
a=(70deg)
Stop lever angle
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 15 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:
Start By:a. remove oil pump1. Check the connecting rods and caps for their identification and location. 2. Turn the crankshaft until the connecting rod caps are in position.3. Remove two bolts (1) and the cap from the connecting rod. Remove the lower half of the bearing from the cap.4. Push the connecting rod away from the crankshaft. Remove the upper half of the bearing from the connecting rod. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.5. Install the upper half of the bearing in the connecting rod.6. Pull the connecting rod slowly on to the crankshaft.7. Install the lower half of the bearing in the cap. Be sure the tabs in the back of bearings are in the tab grooves of the connecting rod and cap.The serviceman must be very careful to use Plastigage, Tool (A) correctly. The following points must be remembered:Make sure that the backs of the bearings and the bores are clean and dry.Make sure that the bearing locking tabs are properly seated in their slots.The crankshaft must be free of oil where the Plastigage touches it.Put a piece of Plastigage (A) on the crown of the bearing half that is in the cap. Do not allow the Plastigage to extend over the edge of the bearing.Install the bearing cap using the correct torque-turn specifications. Do not use an impact wrench. Be careful not to dislodge the bearing when the cap is installed.Do not turn the crankshaft with the Plastigage installed.Carefully remove the cap but do not remove the Plastigage. Measure the width of the Plastigage while it is in the bearing cap or on the crankshaft journal. Do this by using the correct scale on the package. Record the measurements.Remove the Plastigage before reinstalling the cap.When using Plastigage, the readings can sometimes be unclear. For example, all parts of the Plastigage are not the same width. Measure the major widths to make sure that they are within the specification range. Also, experience has shown that when checking clearances tighter than 0.10 mm (.004 in) the readings may be low by 0.013 to 0.025 mm (.0005 to .0010 in). Out-of-round journals can give faulty readings. Also, journal taper may be indicated when one end of the Plastigage is wider that the other.For complete details concerning measuring bearing clearance, see the topic, "Engine Bearings & Crankshafts", SEBD0531. 8. Use Plastigage (A) to check the bearing clearance.9. Put Plastigage (A) on the bearing.10. Put 2P2506 Thread Lubricant on the threads of the rod bolts and seat surfaces of the nuts. Be sure the cylinder numbers on the rod cap and rod are the same and are on the same side of connecting rod. Numbers are on the same side of the rod and cap as are the bearing tab slots. If new rods are installed, put the cylinder number on the rod and cap. Do not turn the crankshaft when Plastigage (A) is in position.