104742-7592 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047427592 6274711120

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104742-7592 1047427592

KOMATSU 6274711120 6274711120

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 104742-7592 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 104742-7592 1047427592

KOMATSU 6274711120 6274711120

Zexel num

Bosch num

Firm num

Name

104742-7592

6274711120 KOMATSU

INJECTION-PUMP ASSEMBLY
SAA4D95LE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

Transfer pump pressure kPa 20 20 20

Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side)
Right R

Timer measuring device installation position
Low pressure side LOW PRESSURE SIDE

Injection timing adjustment

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 73.3 72.8 73.8

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 800 800 800

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 110.2 109.7 110.7

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 800 800 800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 117.9 117.4 118.4

Difference in delivery mm3/st. 9.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 73.3 72.3 74.3

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 800 800 800

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Average injection quantity mm3/st. 110.2 108.7 111.7

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 800 800 800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 117.9 116.4 119.4

Difference in delivery mm3/st. 10

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 1100 1100 1100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 122.1 116.1 128.1

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 1253 1253 1253

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 30.8 26.8 34.8

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_02

Pump speed r/min 1428 1428 1428

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 5

Oil temperature degC 50 48 52

Injection quantity adjustment_03

Pump speed r/min 1253 1253 1253

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 30.8 26.3 35.3

Basic *

Oil temperature degC 50 48 52

Governor adjustment

Pump speed r/min 418 418 418

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 7.2 5.2 9.2

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 418 418 418

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 7.2 4.7 9.7

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 130.5 125.5 135.5

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 130.5 125.5 135.5

Oil temperature degC 48 46 50

Remarks
IDLE

Speed control lever angle

Pump speed r/min 418 418 418

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1100 1100 1100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Overflow quantity cm3/min 630 500 760

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1100 1100 1100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 402 382 422

Pressure kgf/cm2 4.1 3.9 4.3

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Stop lever angle_02

Pump speed r/min 800 800 800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 275 226 324

Pressure kgf/cm2 2.8 2.3 3.3

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 373 324 422

Pressure kgf/cm2 3.8 3.3 4.3

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1100 1100 1100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure kPa 402 373 431

Pressure kgf/cm2 4.1 3.8 4.4

Basic *

Oil temperature degC 50 48 52

Remarks
Full

0000001101

Pump speed r/min 1100 1100 1100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 0.7 0.5 0.9

Basic *

Oil temperature degC 50 48 52

Remarks
Full

_02

Pump speed r/min 800 800 800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 0.3

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke mm 0.7 0.4 1

Basic *

Oil temperature degC 50 48 52

Remarks
Full

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 800 800 800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 21 20 22

Timer stroke TA mm 1.6 1.3 1.9

Timer stroke variation dT mm 1.6 1.6 1.6

Basic *

Oil temperature degC 50 48 52

Remarks
Reverse operation

_02

Pump speed r/min 800 800 800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 21 19.5 22.5

Timer stroke TA mm 1.6 1.2 2

Timer stroke variation dT mm 1.6 1.6 1.6

Basic *

Oil temperature degC 50 48 52

Remarks
Reverse operation

_03

Pump speed r/min 800 800 800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 10 8 12

Timer stroke TA mm 2 2

Timer stroke variation dT mm 2 2

Oil temperature degC 50 48 52

Remarks
Reverse operation

Timing setting

K dimension mm 3.1 3 3.2

KF dimension mm 5.5 5.4 5.6

MS dimension mm 1.4 1.3 1.5

BCS stroke mm 2.7 2.5 2.9

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 16 12 20

Control lever angle beta deg. 29 24 34

Test data Ex:

0000001601 BOOST COMPENSATOR ADJUSTMENT

BCS adjustment procedure 1. At full boost pressure, set so that the full injection quantity is within the specifications (adjusting point). 2. Perform boost compensator intermediate operation point adjustment (pump speed N1, boost pressure P1). 3. When injection quantity at boost pressure P2 and pump speed N2 is not as specified, loosen nut (A) and adjust position of screw (B) so that injection quantity is as specified. The screw position should be within +-1 turn of initial position. 4. The nut tightening torque is T.
----------
N1=800r/min N2=500r/min P1=40.0kPa(300mmHg) P2=0kPa(0mmHg) T=6~9N-m(0.6~0.9kgf-m)
----------
SW=10mm T=6~9N-m(0.6~0.9kgf-m)

0000001801 W-CSD ADJUSTMENT

Adjustment of the W-CSD Adjustment of the timer advance angle 1. Determine the timer advance angle using the graph (graph TA). X:Temperature t (deg C) Y:Timer stroke TA (mm) (S) Cold advance (R) Cooling water temperature (deg C) (T) Timer piston stroke (mm) (B) Standard point
----------
TA=-0.053t+3.881 -3<=t<=20 TA=-0.0517t+3.854 20<=t
----------
a=76.5++degC b=20degC c=-3degC d=0mm e=2.82+-0.4mm f=4.04+-0.6mm

0000001901 STARTING I/Q ADJUSTMENT

Starting Q decrease lever adjustment Adjust using the screw (A) so that the standards are satisfied, then fix using the nut (B). Screw (A) protrusion: L (B) Nut (SW10, T1 after completing adjustment) (C) Stop lever
----------
L=7.4~11.1mm T1=6~9N-m(0.6~0.9kgf-m)
----------
L=7.4~11.1mm

0000002001 TAMPER PROOF

Tamperproof installation procedure A:Cap B:Rubber vibration damper C:Nut D:Cap E:Position of break L1:Inspection dimension Fig. 1 Regulating valve seal 1) Insert the cap A horizontally (press fit). 2) After insertion (press-fitting), tighten the cap to torque T1, and confirm that it is not pulled out at load F1. Fig.2 Full load adjusting screw 1) Confirm the position of the rubber vibration damper (B) and then tighten nut (C) to the torque T2. Fig. 3 External-adjustment type cover governor seal 1) Target breaking torque T3
----------
L1=23~28mm F1=49N(5kgf) T1=4.9N-m(0.5kgf-m) T2=7~9N-m(0.7~0.9kgf-m) T3=2.94~4.41N-m(0.3~0.45kgf-m)
----------
L1=23~28mm

Information:

1. Disconnect fuel lines (1) from fuel transfer pump (3). Remove bolts (2). Remove fuel transfer pump (3). Remove gasket from fuel transfer pump.2. Install a new gasket on fuel transfer pump (3). Install fuel transfer pump on rear plate with the bolts (2) that hold it. Connect fuel lines (1) to the fuel transfer pump.Disassemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Remove tachometer drive (3) from transfer pump cover (4).2. Remove bolts (1). Make a separation between cover (4) and pump body (2). 3. Remove lip-type seal (6) from the cover. Remove plug (5), seal, spring and plunger (bypass valve) from the cover. 4. Remove nut (10) from shaft (7). Remove gear (9) and key (11).5. Remove shaft (7) and gear (8) as a unit. Remove gear (8) from drive shaft (7) with a press.6. Remove idler gear (12). 7. Remove bushing (14), two lip-type seals and the bottom bearing from pump body (1).8. Remove check valve (13). Assemble Fuel Transfer Pump
1. Install bushing (4) in body (3) with Tooling (B). The bushing must not be extended above the (gear) surface of the body.2. Install the check valve in the body with Tooling (A).3. Install lip-type seal (5) with Tooling (C). Install the seal until it is 24.6 0.5 mm (97 .02) from the bottom surface of body (3) and with the lip toward bushing (4) as shown.4. Install lip-type seal (6) with Tooling (D). Install the seal until it is 14.2 0.5 mm (.56 .02 in) from the bottom surface of body (3) and with the lip away from seal (5) as shown.5. Install bearing (7) in body (3) with Tooling (E). The bearing must be even with the surface of the pump body. 6. Heat gear (8) to a maximum temperature of 316°C (600°F). Install gear (8) on shaft (11) until dimension (X) is 49.71 0.25 mm (1.957 0.10 in).7. Install the drive shaft and gear in body (3). Install key, gear (10) and nut (9). Tighten the nut to a torque of 28 7 N m (22 5 lb ft).8. Install idler gear (12) in body (3).9. Install lip-type seal (2) with Tooling (C). Install the seal until it is 3.8 0.5 mm (.15 .02 in) from the top surface of cover (1) with the lip toward the inside as shown. 10. Install plunger (14) (bypass valve), spring (15), seal plug (13) in pump cover (1). Tighten plug (13) to a torque of 28 4 N m (27 3 lb ft).11. Put 7M-7260 Liquid Gasket Material on the surface of cover (1). Install cover (1) on pump body.
Do not let the liquid gasket enter the pump.
The drive shaft must turn freely after the bolts that hold the transfer pump together are tightened.12. Install tachometer drive on transfer pump cover (1).End By:a. install fuel transfer pump