106675-4500 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066754500

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106675-4500 1066754500

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Service parts 106675-4500 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0381

3. GOVERNOR 105407-6870

4. SUPPLY PUMP

105217-6030

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0431

7. COUPLING PLATE 156637-2820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-4540

11. Nozzle and Holder 6152-12-3100

12. Open Pre:MPa(Kqf/cm2) 27.5{280}

13. NOZZLE-HOLDER 105041-7130

14. NOZZLE

105025-0120

15. NOZZLE SET

Include in #1:

106675-4500 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106675-4500 1066754500

Zexel num

Bosch num

Firm num

Name

106675-4500
106675-4504

KOMATSU

INJECTION-PUMP ASSEMBLY
SA6D125 *

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9.5

Pump speed r/min 1025 1025 1025

Average injection quantity mm3/st. 177.5 175.5 179.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 5.7+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 13 11.5 14.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 170 160 180

Fixing the lever *

Rack limit *

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)Rack difference between N = N1 and N = N2
----------
K=16 N1=1025r/min N2=230r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Use the hole at R = aa
----------
aa=85mm
----------
a=9deg+-5deg b=23deg+-5deg c=35deg+-3deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(150deg)

Information:

Introduction
This Special Instruction is intended for the installation of the 366-9748 Injector Wiring Harness Kit . The 366-9748 Injector Wiring Harness Kit can be used to repair TPI connectors. TPI connectors can be found on HEUI injectors, variable valve actuators, and Cat Brakes.Removal of the Connector From the Wire Harness
Table 1
Required Tools
Tool Part Number Part Description Qty
A 9S-9150 Terminal Crimp Tool As 1
B 9U-6070
or Heat Gun Gp
(110V) 1
9U-6072 Heat Gun Gp (220 V) The following steps will remove the connector for an injector from the wire harness that is under the valve mechanism cover.
Illustration 1 g01035448
(1) Side "A" of the connector (2) Side "B" of the connectorNote: Side "A" or side "1" of the connector is the output signal wire from the ECM. Side"B" or side "2" of the connector is the sensor return.
Identify side "A" of the connector and identify side "B" of the connector.
Mark each wire on the wire harness before the wires are cut. Most connectors will have the label of an "A" and a "B". Some connectors may have a "1" and a "2" that is on the connector. The label with a "1" will be an "A". The label with a "2" will be a "B".
Illustration 2 g01034438
Connector that is cut from the wire harness (3) Wire on side "A" of the connector (4) Wire on side "B" of the connector
Cut wire (3) at a distance of 45 mm (1.8 inch).
Cut wire (4) at a distance of 40 mm (1.6 inch).
Illustration 3 g01034450
(5) Wire from the harness for side "B" on the connector (6) Wire from the harness for side "A" on the connectorNote: The wires on the old connector are cut to length so that the wires on the wire harness to the new connector will match up. The proper length will help in matching the harness wires to the wires on the new connector wires.
Discard the connector.Installation Procedure for the Connector
Use Tool (A) to strip the plastic off wires (5) and (6) at a distance of 5 mm (0.19 inch).
Illustration 4 g01034451
Connecting the connector to the wire harness (5) Wire from the harness for side "B" on the connector (6) Wire from the harness for side "A" on the connector (7) Heat shrink tube (8) Butt splice on wire (4) that is on side "B" of the connector (9) Butt splice on wire (3) that is on side "A" of the connector
Use the heat shrink tubes from 366-9748 Injector Wiring Harness Kit . Slide the heat shrink tubes toward the connector in order to expose the butt splices.
Take wire (5) and slide wire (5) in the butt splice (8).
Take wire (6) and slide wire (6) in the butt splice (9).
Illustration 5 g01035814
Illustration 6 g01034452
(8) Butt splice on wire (4) that is on side "B" of the connector (9) Butt splice on wire (3) that is on side "A" of the connector
Use Tool