Information injection-pump assembly
ZEXEL
106682-4741
1066824741
KOMATSU
6212711882
6212711882
Rating:
Service parts 106682-4741 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:
106682-4741
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106682-4741
1066824741
KOMATSU
6212711882
6212711882
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
14.1
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
311
306
316
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
D
Rack position
8.2+-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
*
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
320
320
340
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Minimum - maximum speed specification
(2)Target notch: K
(3)RACK LIMIT
(4)Load lever stop (with the speed lever at full)
(5)Idle sub spring setting: L1.
(6)Variable speed specification: idling adjustment
(7)Main spring setting
----------
K=13 L1=7.8-0.5mm
----------
----------
K=13 L1=7.8-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa
(2)Set the pump speed at bb (at delivery)
(3)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=5deg+-5deg b=12deg+-5deg c=25deg+-5deg
----------
aa=750r/min bb=900r/min
----------
a=5deg+-5deg b=12deg+-5deg c=25deg+-5deg
0000000901
F:Full load
I:Idle
S:Stop
(1)Use the hole at R = aa
----------
aa=27mm
----------
a=(26.5deg)+-5deg b=31deg+-5deg c=53deg+-5deg
----------
aa=27mm
----------
a=(26.5deg)+-5deg b=31deg+-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 flywheel The crankshaft rear seal and wear sleeve come as a set and must be installed as a set. If a replacement of the seal is to be made, a replacement of the wear sleeve must also be made. 1. Make at least three holes in seal (1) with a hammer and a sharp punch. 2. Use tool (A) to remove seal (1). 3. Install tool (C) in the seal bore.4. Install tool (B) between tool (C) and wear sleeve (2). Turn tool (B) until the tool makes a dent (crease) in wear sleeve (2). Do this in three or more places until the wear sleeve is loose.5. Remove tools (B) and (C), and remove wear sleeve (2) from the crankshaft.Install Crankshaft Rear Seal And Wear Sleeve
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instruction, Form No. SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
1. Install the rear crankshaft seal and wear sleeve with tooling (A). Use the procedure which follows: a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the crankshaft outside diameter before the wear sleeve is installed on the crankshaft. Do not let any Quick Cure Primer or Retaining Compound get on the lip of the seal.b. Install locator (1) and the bolts on crankshaft (3).c. The seal and wear sleeve must be installed dry. Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the rear seal group for an engine is different from the front seal group. If a seal group is installed on the wrong side of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
d. Put wear sleeve (2) and seal (6) as a unit in position on locator (1).e. Put installer (4) in position on locator (1).f. Put clean engine oil on the face of nut (5) and its contact area on installer (4). Install nut (5) on locator (4).g. Tighten nut (5) until installer (4) makes contact with locator (1).h. Remove tooling (A) from the crankshaft seal and wear sleeve. Tooling (A) will install the seal and wear sleeve to the correct depth on the crankshaft.END BY:a. install flywheel
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instruction, Form No. SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
1. Install the rear crankshaft seal and wear sleeve with tooling (A). Use the procedure which follows: a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the crankshaft outside diameter before the wear sleeve is installed on the crankshaft. Do not let any Quick Cure Primer or Retaining Compound get on the lip of the seal.b. Install locator (1) and the bolts on crankshaft (3).c. The seal and wear sleeve must be installed dry. Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the rear seal group for an engine is different from the front seal group. If a seal group is installed on the wrong side of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
d. Put wear sleeve (2) and seal (6) as a unit in position on locator (1).e. Put installer (4) in position on locator (1).f. Put clean engine oil on the face of nut (5) and its contact area on installer (4). Install nut (5) on locator (4).g. Tighten nut (5) until installer (4) makes contact with locator (1).h. Remove tooling (A) from the crankshaft seal and wear sleeve. Tooling (A) will install the seal and wear sleeve to the correct depth on the crankshaft.END BY:a. install flywheel