Information injection-pump assembly
ZEXEL
106671-9440
1066719440
KOMATSU
6211721120
6211721120
Rating:
Service parts 106671-9440 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6211-12-3500
12.
Open Pre:MPa(Kqf/cm2)
24.5{250}
15.
NOZZLE SET
Include in #1:
106671-9440
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106671-9440
1066719440
KOMATSU
6211721120
6211721120
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
131424-3420
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
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
Adjusting point
A
Rack position
10.1
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
143.5
141.5
145.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
54.7
54.7
Boost pressure
mmHg
410
410
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.9+-0.5
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
8.5
7
10
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
220
210
230
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R1-0.95
Boost pressure
kPa
21.3
18.6
24
Boost pressure
mmHg
160
140
180
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(10.55
)
Boost pressure
kPa
41.3
34.6
48
Boost pressure
mmHg
310
260
360
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Boost compensator stroke: BCL
(5)Rack difference between N = N1 and N = N2
----------
K=10 BCL=0.95+-0.1mm N1=950r/min N2=650r/min
----------
----------
K=10 BCL=0.95+-0.1mm N1=950r/min N2=650r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=35deg+-5deg b=24deg+-5deg c=3deg+-3deg
----------
----------
a=35deg+-5deg b=24deg+-5deg c=3deg+-3deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(10deg)
----------
----------
a=(10deg)
Information:
Introduction
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.The actuator and pump groups of these fuel injectors are sensitive to debris in the oil. The injector may malfunction due to debris in the oil, causing seizure, or high leaks in components.
Table 1
Revision Table
Revision Summary of Changes
3 Added serial numbers. Improvement Procedure
Clean oil rail after pump failure.Reference: Refer to Special Instruction, REHS3819 for the procedure to clean the oil rail after engine failure to avoid debris in the oil system.
Use clean oil and clean filters.The life of the injector depends on the oil quality. It can be increased if good cleaning practices are performed before installing the injectors.Reference: Refer to Operation and Maintenance Manual, SEBU6250 and Operation and Maintenance Manual, SEBU6251 for direction on oil sampling intervals and optimizing engine oil life.
Illustration 1 g06207717
(1) Actuator
(2) Pump Group
(3) Valve Seat Damage Due to Debris in the Oil SystemInjector Failure Due To Damage From Debris In The Oil May Not Be A Warrantable Failure
Illustration 2 g06244961
Do not perform any procedure in this Special Instruction until you have read the information and you understand the information.The actuator and pump groups of these fuel injectors are sensitive to debris in the oil. The injector may malfunction due to debris in the oil, causing seizure, or high leaks in components.
Table 1
Revision Table
Revision Summary of Changes
3 Added serial numbers. Improvement Procedure
Clean oil rail after pump failure.Reference: Refer to Special Instruction, REHS3819 for the procedure to clean the oil rail after engine failure to avoid debris in the oil system.
Use clean oil and clean filters.The life of the injector depends on the oil quality. It can be increased if good cleaning practices are performed before installing the injectors.Reference: Refer to Operation and Maintenance Manual, SEBU6250 and Operation and Maintenance Manual, SEBU6251 for direction on oil sampling intervals and optimizing engine oil life.
Illustration 1 g06207717
(1) Actuator
(2) Pump Group
(3) Valve Seat Damage Due to Debris in the Oil SystemInjector Failure Due To Damage From Debris In The Oil May Not Be A Warrantable Failure
Illustration 2 g06244961