Information injection-pump assembly
ZEXEL
106682-4920
1066824920
KOMATSU
6212711850
6212711850
Rating:
Service parts 106682-4920 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:
106682-4920
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106682-4920
1066824920
KOMATSU
6212711850
6212711850
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
12.3
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
357
352
362
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.3+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
9.5
8
11
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT: RAL
----------
K=24 RAL=14.7+0.2mm
----------
----------
K=24 RAL=14.7+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(25.5deg)+-5deg b=(34.5deg)+-5deg
----------
----------
a=(25.5deg)+-5deg b=(34.5deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)No return spring
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-5deg b=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:
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove coolant from the engine.2. Loosen two hose clamps (3) and slide hose from tube assembly (2).3. Disconnect tube assembly (1) at the aftercooler cover.4. Remove four bolts holding the tube assembly to the aftercooler housing. Remove tube assembly (2). 5. Remove O-ring seal (4). 6. Remove adapter (5) and the gasket. An O-ring seal on each end of the aftercooler core holds the adapters (5) and (13) in position. 7. Loosen hose clamps (6) and slide hose on the breather tubes. Remove bolt (8) and breather tube (7). 8. Disconnect hose assembly (9).9. Loosen hose clamps (11) and slide the hose from tube assembly (10).10. Remove four bolts fastening the tube assembly to the aftercooler cover. Remove tube assembly (10). 11. Remove O-ring seal (12). 12. Remove adapter (13) and the gasket. 13. Remove the four bolts (14). 14. Remove bolts (17), cover (18) and the gasket. Remove pipe (16). 15. Remove aftercooler core assembly (20) and the gasket. Remove "O'-ring seals (19) from each end of the core. 16. Remove two bolts (21) on the inside of the aftercooler housing. Make a note of the location of bolt spacers before removal. 17. Remove bolts and spacers (23), housing (22) and the gasket. The following steps are to install the jacketwater aftercooler. Inspect all O-ring seals and gaskets and make replacements if necessary. Put a thin layer of clean engine oil on all O-ring seals and in the bores of each adapter.18. Put aftercooler housing gaskets in position on the cylinder head and install aftercooler housing (22). Make a note of the location of two bolts and spacers (23) from the remove story Step 17.19. Install aftercooler core gasket (20).20. Install the O-ring seals (19) on each end of the aftercooler core (20).21. Put the aftercooler core (20) in position in the housing. Put the gasket in place on the core assembly.22. Install turbocharger pipe and the aftercooler cover (18).23. Install four bolts to fasten flange (15) to cover.24. Install gasket and adapter (13). Install breather tube on breather assembly and install the bolt to fasten the breather tube clip to the engine oil cooler.25. Install O-ring seal (12).26. Install tube assembly (10). Slide hose in position and tighten hose clamps.27. Connect hose assembly (9) to tube assembly (10).28. Install gasket and adapter (5).29. Install O-ring seal (4) on tube assembly (2).30. Put tube assembly (2) in position on housing. Make sure tube assembly clip is in place and install the bolts.31. Slide hose in position and tighten two clamps (3).32. Connect tube assembly (1).33. Fill the radiator to the correct level with coolant.
Perform Scheduled Oil Sampling after performing service work to check for coolant leakage and contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.