Information injection-pump assembly
ZEXEL
106682-4550
1066824550
SHINKO-ENGIN.
0160090020
0160090020

Rating:
Cross reference number
ZEXEL
106682-4550
1066824550
SHINKO-ENGIN.
0160090020
0160090020
Zexel num
Bosch num
Firm num
Name
106682-4550
0160090020 SHINKO-ENGIN.
INJECTION-PUMP ASSEMBLY
S613 * K
S613 * K
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-7120
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
1-4-2-6-
3-5
Pre-stroke
mm
3.5
3.45
3.55
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 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
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
12.2
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
244
241
247
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.7+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
20
18
22
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
----------
K=17
----------
----------
K=17
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(25deg)+-5deg b=(43deg)+-5deg
----------
----------
a=(25deg)+-5deg b=(43deg)+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=19deg+-5deg b=53deg+-5deg
----------
----------
a=19deg+-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=(10deg)
----------
----------
a=(10deg)
Information:
start by:a) remove flywheel housingb) remove valve liftersc) remove pistonsd) remove timing gear cover and oil pump1. Fasten a hoist and put the engine in position on tool (A).2. Turn the crankshaft until the timing mark on the crankshaft gear is in alignment with the timing mark on the camshaft gear. For more detail about removal of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS. 3. Remove bolts (1) and main bearing caps (2). Remove the lower halves of the main bearings from the caps.4. Install two of the bolts that hold the flywheel in place in the end of crankshaft. 5. Fasten a hoist and remove crankshaft (3) from the engine. The weight of the crankshaft is 54 kg (120 lb.).
Be careful not to cause damage to the crankshaft journals when the crankshaft is removed.
6. Remove the upper halves of the main bearings from the cylinder block.7. Install tooling (B) and remove the gear from the crankshaft. Install Crankshaft And Gear
1. Install the key for the crankshaft gear so it is even with the end of the crankshaft.2. Heat the crankshaft gear to a maximum temperature of 260°C (500°F). Install the gear on the crankshaft with the timing mark on the gear toward the pulley end of the crankshaft.3. Install the thrust bearing for the No. 4 main. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.4. Install the upper main bearings (the bearings with oil hole) into the engine block.5. Install two of the bolts that hold the flywheel in place in the end of the crankshaft. Fasten a hoist and put the crankshaft in position in the block. Make sure the timing mark on the crankshaft gear is in alignment with the timing mark on the camshaft gear. For more detail about installation of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS.
When the bearing caps are installed, make sure the number on the side of the cap is next to and respective with the number on the engine block.
When the bearing clearance is checked and the engine is in a vertical position, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the upper halves of the main bearings to get a correct measurement with Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary to hold the crankshaft up. Do not turn crankshaft when Plastigage is in position to check clearance. 6. Check the bearing clearance with Plastigage. Put the lower main bearings into the caps. Put the caps in position and install the bolts. Tighten the bolts in number sequence as follows: a) Tighten bolts 1 through 10 to a torque of 40 4 N m (30 3 lb.ft.).
Do not use an impact
Be careful not to cause damage to the crankshaft journals when the crankshaft is removed.
6. Remove the upper halves of the main bearings from the cylinder block.7. Install tooling (B) and remove the gear from the crankshaft. Install Crankshaft And Gear
1. Install the key for the crankshaft gear so it is even with the end of the crankshaft.2. Heat the crankshaft gear to a maximum temperature of 260°C (500°F). Install the gear on the crankshaft with the timing mark on the gear toward the pulley end of the crankshaft.3. Install the thrust bearing for the No. 4 main. Install the bearings dry when the clearance checks are made. Put clean engine oil on the bearings for final assembly.4. Install the upper main bearings (the bearings with oil hole) into the engine block.5. Install two of the bolts that hold the flywheel in place in the end of the crankshaft. Fasten a hoist and put the crankshaft in position in the block. Make sure the timing mark on the crankshaft gear is in alignment with the timing mark on the camshaft gear. For more detail about installation of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS.
When the bearing caps are installed, make sure the number on the side of the cap is next to and respective with the number on the engine block.
When the bearing clearance is checked and the engine is in a vertical position, the crankshaft will have to be lifted up with a force equal to the weight of the crankshaft and held against the upper halves of the main bearings to get a correct measurement with Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary to hold the crankshaft up. Do not turn crankshaft when Plastigage is in position to check clearance. 6. Check the bearing clearance with Plastigage. Put the lower main bearings into the caps. Put the caps in position and install the bolts. Tighten the bolts in number sequence as follows: a) Tighten bolts 1 through 10 to a torque of 40 4 N m (30 3 lb.ft.).
Do not use an impact
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Niigata-Urawa
Niigata-Tekkou
Komatsu
Komatsu
Komatsu
Shinko-Engin.
106682-4550
0160090020
INJECTION-PUMP ASSEMBLY
S613
S613