Information injection-pump assembly
ZEXEL
106672-9540
1066729540
KOMATSU
6127711150
6127711150
Rating:
Service parts 106672-9540 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6127-11-3104
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106672-9540
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106672-9540
1066729540
KOMATSU
6127711150
6127711150
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
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
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
2.5
2.45
2.55
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
12.5
Pump speed
r/min
1000
1000
1000
Each cylinder's injection qty
mm3/st.
251
246
256
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
6.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
36.9
32.9
40.9
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
13.3+-0.
5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
275
265
285
Fixing the lever
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Rack difference between N = N1 and N = N2
----------
K=20 N1=1000r/min N2=450r/min
----------
----------
K=20 N1=1000r/min N2=450r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=19deg+-5deg b=31deg+-3deg c=33deg+-5deg
----------
----------
a=19deg+-5deg b=31deg+-3deg c=33deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of spline gear's aligning mark at No 1 cylinder's beginning of injection (key position)
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
ACTION REQUIRED
1. Refer to Special Instruction, REHS5023, "Replacing the Fuel Injection Pump on Certain C9.3 Engines". Replace the existing 375-5244 or early production 379-0150 common rail fuel injection pump with the new production 379-0150 common rail fuel injection pump and new gasket 6V-8260. Install a new 356-5214 fuel line from the common rail fuel injection pump to the fuel rail.
2. Refer to C9.3 Disassembly and Assembly, KENR8149 "Engines for Caterpillar Built Machines". Replace the prior 362-0770 Pressure Relief Valve with 415-4991 Pressure Relief Valve, and 228-7102 O-ring.
3. Refer to Service Magazine, SEPD1818, "An Improved Fuel Injection Pump Group Is Used on Certain C9.3 Machine Engines", in order to record the common rail fuel injection pump serial number. This serial number must be entered into the containment service letter claim story.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-4000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
4001-6000 hrs,
37-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 12.0-hour job for Group 1
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-4000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
4001-6000 hrs,
37-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 16.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.