104747-7010 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047477010 6272711210


 

Information injection-pump assembly

ZEXEL 104747-7010 1047477010
KOMATSU 6272711210 6272711210
104747-7010 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 104747-7010 1047477010
KOMATSU 6272711210 6272711210


Zexel num
Bosch num
Firm num
Name
104747-7010 
 
6272711210  KOMATSU
INJECTION-PUMP ASSEMBLY
P161/CUMM

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
Injection timing adjustment
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   60.2 59.7 60.7
Difference in delivery mm3/st.   4.5
Basic   *
Oil temperature degC   50 48 52
Injection timing adjustment_02
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   53.6 49.1 58.1
Oil temperature degC   48 46 50
Injection timing adjustment_03
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   61.3 57.3 65.3
Oil temperature degC   50 48 52
Injection timing adjustment_04
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   60.2 58.7 61.7
Difference in delivery mm3/st.   5
Basic   *
Oil temperature degC   50 48 52
Injection timing adjustment_05
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   49.5 45.5 53.5
Oil temperature degC   50 48 52
Injection quantity adjustment
Pump speed r/min   1425 1425 1425
Average injection quantity mm3/st.   16 13 19
Difference in delivery mm3/st.   4.5
Basic   *
Oil temperature degC   50 48 52
Injection quantity adjustment_02
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   3
Oil temperature degC   50 48 52
Injection quantity adjustment_03
Pump speed r/min   1425 1425 1425
Average injection quantity mm3/st.   16 11.5 20.5
Basic   *
Oil temperature degC   50 48 52
Governor adjustment
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   8.6 6.6 10.6
Difference in delivery mm3/st.   2
Basic   *
Oil temperature degC   48 46 50
Governor adjustment_02
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   8.6 6.1 11.1
Difference in delivery mm3/st.   2.5
Basic   *
Oil temperature degC   48 46 50
Timer adjustment
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   80 75 85
Basic   *
Oil temperature degC   48 46 50
Remarks
IDLE
 
Timer adjustment_02
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   80 75 85
Oil temperature degC   48 46 50
Remarks
IDLE
 
Speed control lever angle
Pump speed r/min   400 400 400
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   1300 1300 1300
Overflow quantity cm3/min   430 300 560
Oil temperature degC   50 48 52
Stop lever angle
Pump speed r/min   1300 1300 1300
Pressure kPa   559 539 579
Pressure kgf/cm2   5.7 5.5 5.9
Basic   *
Oil temperature degC   50 48 52
Stop lever angle_02
Pump speed r/min   800 800 800
Pressure kPa   422 373 471
Pressure kgf/cm2   4.3 3.8 4.8
Oil temperature degC   50 48 52
Stop lever angle_03
Pump speed r/min   1100 1100 1100
Pressure kPa   500 451 549
Pressure kgf/cm2   5.1 4.6 5.6
Oil temperature degC   50 48 52
Stop lever angle_04
Pump speed r/min   1300 1300 1300
Pressure kPa   559 530 588
Pressure kgf/cm2   5.7 5.4 6
Basic   *
Oil temperature degC   50 48 52
0000001101
Pump speed r/min   1300 1300 1300
Timer stroke mm   4.4 4.2 4.6
Basic   *
Oil temperature degC   50 48 52
_02
Pump speed r/min   800 800 800
Timer stroke mm   1.6 1.1 2.1
Oil temperature degC   50 48 52
_03
Pump speed r/min   1300 1300 1300
Timer stroke mm   4.4 4.1 4.7
Basic   *
Oil temperature degC   50 48 52
0000001201
Max. applied voltage V   16 16 16
Test voltage V   25 24 26
0000001401
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   39 38 40
Timer stroke TA mm   3.6 3.4 3.8
Timer stroke variation dT mm   0.8 0.8 0.8
Basic   *
Oil temperature degC   50 48 52
_02
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   39 37.5 40.5
Timer stroke TA mm   3.6 3.3 3.9
Timer stroke variation dT mm   0.8 0.8 0.8
Basic   *
Oil temperature degC   50 48 52
_03
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   30 28 32
Timer stroke TA mm   2.7 2.2 3.2
Timer stroke variation dT mm   1.7 1.7 1.7
Oil temperature degC   50 48 52
Timing setting
K dimension mm   3.3 3.2 3.4
KF dimension mm   5.8 5.7 5.9
MS dimension mm   2 1.9 2.1
Control lever angle alpha deg.   16 12 20
Control lever angle beta deg.   33 28 38

Test data Ex:

0000001801 W-CSD ADJUSTMENT

Test data 104747-7010
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 -3degC<=t<=20degC TA=-0.0517t+3.854 20degC<=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

Test data 104747-7010
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

Test data 104747-7010
Tamperproof installation procedure A:Cap B:Rubber vibration damper C:Nut D:Cap 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.
----------
L1=23~28mm F1=49N(5kgf) T1=4.9N-m(0.5kgf-m) T2=7~9N-m(0.7~0.9kgf-m)
----------
L1=23~28mm




Information:

3176 ATAAC Truck Engine Model Views
Oil Filter (1), Coolant Conditioner Element (2), Thermostat Housing (3), Oil Filter (4) and Turbocharger (5).
Fuel Filter and Priming Pump (6), Electronic Governor and Personality Module (7), Crankcase Breather (8), Grounding Stud (9).Engine Information
The Caterpillar 3176 ATAAC Diesel Truck engine is an 629 cu.in. (10.3 L) displacement, 4.9 in. (125 mm) bore, 5.5 in. (140 mm) stroke, four stroke cycle, 6 cylinder engine. The firing order is 1-5-3-6-2-4 and the direction of rotation is counterclockwise, as viewed from the flywheel. The 3176 is an electronically controlled, mechanically actuated unit injector diesel engine. Timing advance is achieved by precise control of injector firing. Engine speed is controlled by adjusting the firing duration. A speed timing sensor provides information to the fuel cooled ECM (Electronic Control Module) for detection of cylinder position and engine speed.The 3176 electronic engine control system was designed to provide electronic governing, automatic air-fuel ratio control, torque rise shaping, injection timing control and system diagnostics.Additional benefits such as improved cold starting capability, tamper resistance, diagnostics, cruise control, vehicle speed limiting, progressive shift engine speed control, PTO governor and American Trucking Association (ATA) data link and an Engine Monitoring Package (if equipped) provide for additional engine fuel economy, driver comfort and serviceability.The fuel system is a mechanically actuated, electronically controlled unit injector combining the pumping, electronic fuel metering and injecting elements in a single unit to produce higher injection pressures (22,000 psi [151 600 kPa]). High injection pressures help to reduce fuel consumption and particulate emissions.The use of this type of unit injector provides total electronic control of injection timing. The injection timing is varied as a function of engine operating conditions. This optimizes the engine's performance for starting, emissions, noise, fuel consumption and driveability.The 3176 has built-in diagnostics to assure that all components are functioning and operating properly. In the event of a system component deviation from programmed limits, the operator will be alerted to the condition by a dashboard mounted CHECK ENGINE/DIAGNOSTIC lamp.A Caterpillar service tool may be used to read the numerical code of the faulty component. Intermittent faults are logged and stored in the system memory. Refer to Engine Diagnostics section of this publication for alternative methods.The cooling system consists of a gear driven centrifugal pump, with one thermostat which regulates the engine coolant water temperature, a plate type oil cooler and a radiator incorporating a shunt system.The 3176 does not have a cylinder block water cooling system. Instead, the cast water manifold in the spacer deck distributes 65% of the coolant volume to each of the cylinder liners and the remaining 35% flows directly to the cylinder head.The engine lubricating oil, which is both cooled and filtered, is supplied by a gear-type pump. Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high, or if either the oil cooler or the oil filter elements (paper cartridge) should become plugged.Engine efficiency, efficiency of emission controls and engine performance depend on adherence

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