Information injection-pump assembly
ZEXEL
106682-4721
1066824721
KOMATSU
6212711862
6212711862
Rating:
Service parts 106682-4721 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6212-11-3202
12.
Open Pre:MPa(Kqf/cm2)
24.5{250}
15.
NOZZLE SET
Include in #1:
106682-4721
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106682-4721
1066824721
KOMATSU
6212711862
6212711862
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 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
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
3.5
3.45
3.55
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
16.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
423
418
428
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7.8+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
17
15.5
18.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Minimum - maximum speed specification
(2)Target notch: K
(3)Tolerance for racks not indicated: +-0.05mm.
(4)RACK LIMIT: R1
(5)Idle sub-spring setting: L1
(6)Load lever stop (with the speed lever at full)
(7)Variable speed specification: idling adjustment
(8)Main spring setting
----------
K=14 R1=17.4+0.2mm L1=7.8-0.5mm
----------
----------
K=14 R1=17.4+0.2mm L1=7.8-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Pump speed = aa
(2)Pump speed = bb (at delivery)
(3)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=8deg+-5deg b=13deg+-5deg c=29deg+-5deg
----------
aa=750r/min bb=900r/min
----------
a=8deg+-5deg b=13deg+-5deg c=29deg+-5deg
0000000901
F:Full load
I:Idle
S:Stop
(1)Use the hole at R = aa
(2)Without return spring
----------
aa=27mm
----------
a=26.5deg+-5deg b=30.5deg+-5deg c=53deg+-5deg
----------
aa=27mm
----------
a=26.5deg+-5deg b=30.5deg+-5deg c=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(260deg)
----------
----------
a=(260deg)
Information:
START BY:a. remove fuel filter and base1. Drain the coolant from the engine.
Do not disconnect the air line from the compressor governor until the air pressure is zero.
2. Loosen the bleed valve and release the air pressure in the air tank. 3. Disconnect air compressor line (1) and fuel ratio control line (2) from the aftercooler housing. 4. Remove four turbocharger tube adapter to aftercooler housing bolts (3), nuts and cover. Loosen turbocharger compressor housing clamp (4), and rotate turbocharger tube (5) out of the way of the aftercooler housing. 5. Fasten tooling (A) and a hoist to aftercooler housing (6). Remove bolts (7) that hold the aftercooler housing to the cylinder head assembly. Remove the aftercooler housing from the engine. The weight is 36 kg (80 lb.).Install Aftercooler Housing
1. Install new O-ring seals (1) on the aftercooler water inlet and outlet pipes. Lubricate the O-ring seals with clean engine oil. Put new gaskets in position on the cylinder head assembly.2. Fasten tooling (A) and a hoist to aftercooler housing (2), and put the aftercooler housing in position on the water pipes and cylinder head assembly.3. Put 9S3263 Thread Lock on the threads of the bolts, and install the bolts that hold the aftercooler housing to the cylinder head assembly. 4. Rotate turbocharger tube (3) into position. Place a gasket between the aftercooler housing and adapter, and install four bolts and nuts that hold it. Tighten turbocharger clamp nut (4) to a torque of 18 3 N m (13 2 lb.ft.). Lightly hit all around the clamp with a soft faced hammer, and tighten the clamp nut again to the same torque value. 5. Connect air compressor line (5) and fuel ratio control line (6).6. Fill engine with coolant to the correct level. See the Maintenance Guide.END BY:a. install fuel filter and base
Do not disconnect the air line from the compressor governor until the air pressure is zero.
2. Loosen the bleed valve and release the air pressure in the air tank. 3. Disconnect air compressor line (1) and fuel ratio control line (2) from the aftercooler housing. 4. Remove four turbocharger tube adapter to aftercooler housing bolts (3), nuts and cover. Loosen turbocharger compressor housing clamp (4), and rotate turbocharger tube (5) out of the way of the aftercooler housing. 5. Fasten tooling (A) and a hoist to aftercooler housing (6). Remove bolts (7) that hold the aftercooler housing to the cylinder head assembly. Remove the aftercooler housing from the engine. The weight is 36 kg (80 lb.).Install Aftercooler Housing
1. Install new O-ring seals (1) on the aftercooler water inlet and outlet pipes. Lubricate the O-ring seals with clean engine oil. Put new gaskets in position on the cylinder head assembly.2. Fasten tooling (A) and a hoist to aftercooler housing (2), and put the aftercooler housing in position on the water pipes and cylinder head assembly.3. Put 9S3263 Thread Lock on the threads of the bolts, and install the bolts that hold the aftercooler housing to the cylinder head assembly. 4. Rotate turbocharger tube (3) into position. Place a gasket between the aftercooler housing and adapter, and install four bolts and nuts that hold it. Tighten turbocharger clamp nut (4) to a torque of 18 3 N m (13 2 lb.ft.). Lightly hit all around the clamp with a soft faced hammer, and tighten the clamp nut again to the same torque value. 5. Connect air compressor line (5) and fuel ratio control line (6).6. Fill engine with coolant to the correct level. See the Maintenance Guide.END BY:a. install fuel filter and base