104747-7030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047477030 6272711220

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104747-7030 1047477030

KOMATSU 6272711220 6272711220

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Cross reference number

ZEXEL 104747-7030 1047477030

KOMATSU 6272711220 6272711220

Zexel num

Bosch num

Firm num

Name

104747-7030

6272711220 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. 56.2 55.7 56.7

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. 52.3 47.8 56.8

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 57.5 53.5 61.5

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 56.2 54.7 57.7

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 51.5 47.5 55.5

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 1225 1225 1225

Average injection quantity mm3/st. 11.9 8.9 14.9

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_02

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 3

Oil temperature degC 50 48 52

Injection quantity adjustment_03

Pump speed r/min 1225 1225 1225

Average injection quantity mm3/st. 11.9 7.4 16.4

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 1100 1100 1100

Overflow quantity cm3/min 400 270 530

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1100 1100 1100

Pressure kPa 500 480 520

Pressure kgf/cm2 5.1 4.9 5.3

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 700 700 700

Pressure kPa 392 343 441

Pressure kgf/cm2 4 3.5 4.5

Oil temperature degC 50 48 52

Stop lever angle_03

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_04

Pump speed r/min 1100 1100 1100

Pressure kPa 500 471 529

Pressure kgf/cm2 5.1 4.8 5.4

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1100 1100 1100

Timer stroke mm 2.8 2.6 3

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 800 800 800

Timer stroke mm 1.1 0.6 1.6

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Timer stroke mm 2.8 2.5 3.1

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 1100 1100 1100

Average injection quantity mm3/st. 40 39 41

Timer stroke TA mm 2 1.8 2.2

Timer stroke variation dT mm 0.8 0.8 0.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 40 38.5 41.5

Timer stroke TA mm 2 1.7 2.3

Timer stroke variation dT mm 0.8 0.8 0.8

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 30 28 32

Timer stroke TA mm 1.1 0.6 1.6

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. 30 25 35

Test data Ex:

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 -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

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 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:

Torque for Standard Bolts, Nuts and Taperlock Studs
The following charts give general torques for bolts, nuts and taperlock studs of SAE Grade 5 or better quality.
Torques for Bolts and Nuts With Standard Threads
Torques for Taperlock Studs
Use these standard torque values for all fasteners unless otherwise specified in this publication or in the Service Manual.Torque for Metric Fasteners
This product uses 10.9 Grade metric fasteners.
Be very careful never to mix metric with customary (standard) fasteners. Mismatched or incorrect fasteners will cause engine damage or malfunction and may even result in personal injury.Original fasteners removed from the engine should be saved for reassembly whenever possible. If new fasteners are needed, they must be of the same size and grade as the ones that are being replaced.The material strength identification is usually shown on the bolt head by numbers (8.8, 10.9, etc.). Use these standard torque values unless otherwise specified in this publication or the Service Manual.The following charts give general torques for bolts and nuts with Metric Threads of SAE Grade 8.8 or better quality.
Torques for Bolts and Nuts with Metric Threads
Torque for Standard Hose Clamps-Worm Drive Band Type
The following chart gives the torques for initial installation of hose clamps on new hose and for reassembly or tightening of hose clamps on existing hose.
Torque for Constant Torque Hose Clamps
A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new, constant torque hose clamp will help prevent these failures.Each installation application can be different depending on the type of hose, fitting material and anticipated expansion or contraction of the hose and fittings. A torque wrench should be used for proper installation of the new, constant torque hose clamps. Constant torque hose clamps should be installed as follows:* To allow for maximum expansion, install clamps at 50 lb in (5.7 N m).* To allow for equal expansion and contraction, install clamps at 90 lb in (10.2 N m).* To allow for maximum contraction, install clamps at 125 lb in (14.1 N m).