Information injection-pump assembly
ZEXEL
106662-4280
1066624280
KOMATSU
6222731220
6222731220
Rating:
Service parts 106662-4280 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6221-13-3400
12.
Open Pre:MPa(Kqf/cm2)
24.0{245}
15.
NOZZLE SET
Include in #1:
106662-4280
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106662-4280
1066624280
KOMATSU
6222731220
6222731220
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-1420
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)
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
3.9
3.85
3.95
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
(11)
Vist
V
1.8
1.8
1.8
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
96
94.5
97.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Injection quantity adjustment_02
Rack position
(6.2)
Vist
V
2.8
2.7
2.9
Pump speed
r/min
390
390
390
Average injection quantity
mm3/st.
10
8.8
11.2
Max. variation between cylinders
%
0
-15
15
Injection quantity adjustment_03
Remarks
Rack limit setting V = 0.9-0.04
Rack limit setting V = 0.9-0.04
Test data Ex:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Vist = aa, (rack position = bb)
(2)Rack position = cc
----------
aa=0.8V bb=16mm cc=1mm
----------
a=19deg+-5deg b=29deg+-5deg
----------
aa=0.8V bb=16mm cc=1mm
----------
a=19deg+-5deg b=29deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=15deg
----------
a=(50deg)
----------
aa=15deg
----------
a=(50deg)
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.
----------
----------
----------
----------
Information:
Parts Needed
6 - 6I2538 Clip Add injectors and related seals if clip is broken in more than three pieces. Add 336044 O-Ring Seal if thrust pad o-ring is damaged.
Action Required
Parts Stock
Remove all of the following injector groups from parts stock. Rework as described in the attached procedure and return to stock.
4P1410 Injector Group4P1420 Injector Group4P2810 Injector Group4P2820 Injector Group4P9510 Injector Group4P9520 Injector Group4P9610 Injector Group4P9620 Injector Group0R3177 Injector Group0R3178 Injector Group0R3400 Injector GroupAffected Product
Rework the injector groups as described in the attached procedure.
Service Claim Allowances
Parts Stock
Submit one claim for all injector groups removed from parts stock and reworked. List the labor to repair each injector on a separate labor line. A maximum of .2 hours labor per fuel injector will be allowed to remove and install the clip.
Affected Product
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
(1-Rework Procedure)Rework Procedure
Parts Stock or Off Engine
Illustration 1 - 9U5300 Unit Injector Spring Compressor Group
Illustration 2 - Compressor Group In Bench Vice
Illustration 3 - Use caution when handling injectors with missing clips. Loose springs and retainers will allow ball to come loose and fall into the engine.1. Remove injectors from packaging and inspect for a paint stripe across the top face of the spring retainer (either yellow or red). The paint stripe indicates the unit injector has been reworked previously. If a clip has failed and the spring/tappet/plunger are loose, use care during injector removal. The plunger retention ball (see Illustration 3) can drop out and fall into the cylinder/engine.
2. Install service tool in a bench vice as shown in Illustration 2 (position to allow for horizontal installation of injector).3. Use an o-ring pick to remove the o-ring from the injector spring retainer. Remove the rocker arm thrust pad.4. Install the injector in the 9U5300 Unit Injector Spring Compressor Group. Tighten the 5P0541 Nut to compress the spring enough to allow removal of the clip (the clip works like a valve keeper).5. Use a small magnet (pencil size works best) and a suitable clip removal tool to remove the oil clip from the injector. Do not release tension on the spring until a new clip is installed. Releasing tension before a new clip is installed will cause the injector will come apart.
6. Injectors removed from engines only. Inspect the clip that was removed. If the clip is broken in more than three (3) pieces (or if you suspect small pieces have fallen into the injector) the unit injector must be replaced.7. Install a new 6I2538 clip and remove injector from spring compressor group.8. Install thrust pad and thrust pad retaining o-ring. If the thrust pad retaining o-ring is damaged install a new 336044 O-Ring Seal.
9. Mark across the top face of the spring retainer with a yellow paint stripe.10. Repackage new parts and mark "3X" on the box.Affected Product
1. Check for 3X stamped on the block next to the serial number plate. If the block has been stamped do not proceed with the rework unless suspect injectors
6 - 6I2538 Clip Add injectors and related seals if clip is broken in more than three pieces. Add 336044 O-Ring Seal if thrust pad o-ring is damaged.
Action Required
Parts Stock
Remove all of the following injector groups from parts stock. Rework as described in the attached procedure and return to stock.
4P1410 Injector Group4P1420 Injector Group4P2810 Injector Group4P2820 Injector Group4P9510 Injector Group4P9520 Injector Group4P9610 Injector Group4P9620 Injector Group0R3177 Injector Group0R3178 Injector Group0R3400 Injector GroupAffected Product
Rework the injector groups as described in the attached procedure.
Service Claim Allowances
Parts Stock
Submit one claim for all injector groups removed from parts stock and reworked. List the labor to repair each injector on a separate labor line. A maximum of .2 hours labor per fuel injector will be allowed to remove and install the clip.
Affected Product
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
(1-Rework Procedure)Rework Procedure
Parts Stock or Off Engine
Illustration 1 - 9U5300 Unit Injector Spring Compressor Group
Illustration 2 - Compressor Group In Bench Vice
Illustration 3 - Use caution when handling injectors with missing clips. Loose springs and retainers will allow ball to come loose and fall into the engine.1. Remove injectors from packaging and inspect for a paint stripe across the top face of the spring retainer (either yellow or red). The paint stripe indicates the unit injector has been reworked previously. If a clip has failed and the spring/tappet/plunger are loose, use care during injector removal. The plunger retention ball (see Illustration 3) can drop out and fall into the cylinder/engine.
2. Install service tool in a bench vice as shown in Illustration 2 (position to allow for horizontal installation of injector).3. Use an o-ring pick to remove the o-ring from the injector spring retainer. Remove the rocker arm thrust pad.4. Install the injector in the 9U5300 Unit Injector Spring Compressor Group. Tighten the 5P0541 Nut to compress the spring enough to allow removal of the clip (the clip works like a valve keeper).5. Use a small magnet (pencil size works best) and a suitable clip removal tool to remove the oil clip from the injector. Do not release tension on the spring until a new clip is installed. Releasing tension before a new clip is installed will cause the injector will come apart.
6. Injectors removed from engines only. Inspect the clip that was removed. If the clip is broken in more than three (3) pieces (or if you suspect small pieces have fallen into the injector) the unit injector must be replaced.7. Install a new 6I2538 clip and remove injector from spring compressor group.8. Install thrust pad and thrust pad retaining o-ring. If the thrust pad retaining o-ring is damaged install a new 336044 O-Ring Seal.
9. Mark across the top face of the spring retainer with a yellow paint stripe.10. Repackage new parts and mark "3X" on the box.Affected Product
1. Check for 3X stamped on the block next to the serial number plate. If the block has been stamped do not proceed with the rework unless suspect injectors