Information injection-pump assembly
ZEXEL
106682-4880
1066824880
KOMATSU
6166711610
6166711610
Rating:
Service parts 106682-4880 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
6166-11-3100
12.
Open Pre:MPa(Kqf/cm2)
26.0{265}
15.
NOZZLE SET
Include in #1:
106682-4880
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106682-4880
1066824880
KOMATSU
6166711610
6166711610
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
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
2.8
2.75
2.85
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
17.4
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
460
455
465
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Remarks
Standard point A's rack position same as row R
Standard point A's rack position same as row R
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.2+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
36.5
31.5
41.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Idle spring not operating (attached at delivery).
(3)RACK LIMIT: RAL (set using 106684-4120)
(4)Idle sub spring setting: L1.
----------
K=17 RAL=18.9+0.2mm L1=7.3-0.5mm
----------
----------
K=17 RAL=18.9+0.2mm L1=7.3-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa. ( At delivery )
(2)Stopper bolt setting
----------
aa=750r/min
----------
a=10deg+-5deg b=22deg+-5deg
----------
aa=750r/min
----------
a=10deg+-5deg b=22deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=36.5deg+-5deg b=53deg+-5deg
----------
----------
a=36.5deg+-5deg b=53deg+-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)B.T.D.C.: aa
(4)-
----------
aa=34deg
----------
a=(130deg)
----------
aa=34deg
----------
a=(130deg)
Information:
Engine Runs Smoothly
Possible Causes/Corrections
Dirty Air Cleaner/If the air cleaner has a restriction indicator, see if the red piston is in view. If there is no restriction indicator, restriction can be checked with a water manometer or a vacuum gauge (which measures in inches of water). Make a connection to the piping between the air cleaner and the inlet of the turbocharger. Check with the engine running at full load rpm. Maximum restriction is 635 mm (25 in.) of water. If a gauge is not available, visually check the air cleaner element for dirt. If the element is dirty, clean the element or install a new element. Air Inlet Piping Damage or Restriction/Make a visual inspection of the air inlet system and check for damage to piping, rags in the inlet piping, or damage to the rain cap or the cap pushed too far on the inlet pipe. If no damage is seen, check inlet restriction with a clean air cleaner element. Exhaust System Restriction/Make a visual inspection of the exhaust system. Check for damage to piping or for a bad muffler. If no damage is found, you can check the system by checking the back pressure from the exhaust (pressure difference measurement between exhaust outlet and atmosphere). The back pressure must not be more than 1016 mm (40 in.) of water. You can also check by removing the exhaust pipes from the exhaust manifolds. With the exhaust pipes removed, start and load the engine on a chassis dynamometer to see if the problem is corrected. Fuel Injection Timing Not Correct/Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Fuel Setting Is Not Correct/Check and make necessary adjustments as in Testing and Adjusting Section of this Service Manual. See the FUEL SETTING AND RELATED INFORMATION FICHE for the correct fuel setting. Low Quality Fuel/Test the engine with fuel according to recommendations by Caterpillar Tractor Co. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines. Also, Special Instruction, Form No. SEHS6947 has fuel correction factors and tables. Bad Fuel Nozzle(s)/Bad fuel nozzles will normally cause the engine to misfire and run rough, but can cause too much smoke with engine still running smooth. Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual. Valve Adjustment Not Correct or Valve Leakage/Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in.) and exhaust valve clearance is 0.64 mm (.025 in.). Valve leakage normally causes the engine to misfire and run rough. Bad Fuel Injection Pump/An injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the plunger. See the Testing and Adjusting section in this Service Manual for the correct specifications and procedure to check the plungers and lifters.Fuel pumps which are
Possible Causes/Corrections
Dirty Air Cleaner/If the air cleaner has a restriction indicator, see if the red piston is in view. If there is no restriction indicator, restriction can be checked with a water manometer or a vacuum gauge (which measures in inches of water). Make a connection to the piping between the air cleaner and the inlet of the turbocharger. Check with the engine running at full load rpm. Maximum restriction is 635 mm (25 in.) of water. If a gauge is not available, visually check the air cleaner element for dirt. If the element is dirty, clean the element or install a new element. Air Inlet Piping Damage or Restriction/Make a visual inspection of the air inlet system and check for damage to piping, rags in the inlet piping, or damage to the rain cap or the cap pushed too far on the inlet pipe. If no damage is seen, check inlet restriction with a clean air cleaner element. Exhaust System Restriction/Make a visual inspection of the exhaust system. Check for damage to piping or for a bad muffler. If no damage is found, you can check the system by checking the back pressure from the exhaust (pressure difference measurement between exhaust outlet and atmosphere). The back pressure must not be more than 1016 mm (40 in.) of water. You can also check by removing the exhaust pipes from the exhaust manifolds. With the exhaust pipes removed, start and load the engine on a chassis dynamometer to see if the problem is corrected. Fuel Injection Timing Not Correct/Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Fuel Setting Is Not Correct/Check and make necessary adjustments as in Testing and Adjusting Section of this Service Manual. See the FUEL SETTING AND RELATED INFORMATION FICHE for the correct fuel setting. Low Quality Fuel/Test the engine with fuel according to recommendations by Caterpillar Tractor Co. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines. Also, Special Instruction, Form No. SEHS6947 has fuel correction factors and tables. Bad Fuel Nozzle(s)/Bad fuel nozzles will normally cause the engine to misfire and run rough, but can cause too much smoke with engine still running smooth. Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual. Valve Adjustment Not Correct or Valve Leakage/Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in.) and exhaust valve clearance is 0.64 mm (.025 in.). Valve leakage normally causes the engine to misfire and run rough. Bad Fuel Injection Pump/An injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the plunger. See the Testing and Adjusting section in this Service Manual for the correct specifications and procedure to check the plungers and lifters.Fuel pumps which are