104747-7090 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047477090 6273711220

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104747-7090 1047477090

KOMATSU 6273711220 6273711220

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Cross reference number

ZEXEL 104747-7090 1047477090

KOMATSU 6273711220 6273711220

Zexel num

Bosch num

Firm num

Name

104747-7090

6273711220 KOMATSU

INJECTION-PUMP ASSEMBLY
P162/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. 67.2 66.7 67.7

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 57.8 53.3 62.3

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 68.3 64.3 72.3

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 67.2 65.7 68.7

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 62.4 58.4 66.4

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 33.8 30.8 36.8

Difference in delivery mm3/st. 7

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_02

Pump speed r/min 1375 1375 1375

Average injection quantity mm3/st. 3

Oil temperature degC 50 48 52

Injection quantity adjustment_03

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 33.8 29.3 38.3

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 1050 1050 1050

Overflow quantity cm3/min 410 280 540

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1050 1050 1050

Pressure kPa 510 490 530

Pressure kgf/cm2 5.2 5 5.4

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 900 900 900

Pressure kPa 451 402 500

Pressure kgf/cm2 4.6 4.1 5.1

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1000 1000 1000

Pressure kPa 490 441 539

Pressure kgf/cm2 5 4.5 5.5

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1050 1050 1050

Pressure kPa 510 481 539

Pressure kgf/cm2 5.2 4.9 5.5

Basic *

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1050 1050 1050

Timer stroke mm 1.6 1.4 1.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Timer stroke mm 0.4 0 0.9

Oil temperature degC 50 48 52

_03

Pump speed r/min 1050 1050 1050

Timer stroke mm 1.6 1.3 1.9

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 1050 1050 1050

Average injection quantity mm3/st. 50 49 51

Timer stroke TA mm 1 0.8 1.2

Timer stroke variation dT mm 0.6 0.6 0.6

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 50 48.5 51.5

Timer stroke TA mm 1 0.7 1.3

Timer stroke variation dT mm 0.6 0.6 0.6

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 40 38 42

Timer stroke TA mm 0.4 0 0.9

Timer stroke variation dT mm 1.2 1.2 1.2

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

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:

Caterpillar Diesel Truck Engines can operate effectively in cold weather, however, engine operation in cold weather is dependent on the type of fuel used and how well the fuel moves through fuel related components. The purpose of this section is to explain some of the problems and steps that can be taken to minimize fuel problems during cold weather operation when the engine area is colder than 40°F (5°C).Fuel and the Effect from Cold Weather
The two types of diesel fuel available for your truck engine are typically grades No. 1 and No. 2. Although No. 2 diesel fuel is the most commonly used fuel, No. 1 diesel fuel or a blend of No. 1 and No. 2, is the fuel that is best suited for cold weather operation.During cold weather operation, it may be necessary for you to use No. 2 diesel fuel since quantities of No. 1 diesel fuel are limited and generally are only available during the winter months and in the colder climates.There are three major differences between No. 1 and No. 2 diesel fuel. No. 1 diesel fuel has a lower cloud point, a lower pour point and has a lower BTU (kJ) (heat content) rating per unit volume of fuel than the average No. 2 diesel fuel.When using No. 1 diesel fuel, you may notice a drop in power and fuel efficiency, but should not experience any other operating effects.The cloud point is the temperature at which a cloud or haze of wax crystals will begin to form in the fuel and cause fuel filters to plug. The pour point is the temperature which diesel fuel will begin to thicken and be more resistant to flow through fuel pumps and lines.Be aware of these fuel values when purchasing your diesel fuel and anticipate the average outside (ambient) temperature for the area your engine will be operating. Engines fueled in one climate may not operate satisfactorily if moved to another because of problems that result from cold weather.Before troubleshooting for low power or poor performance in winter months, check the type of fuel being used.The use of starting aids, engine oil pan heaters, engine coolant heaters, fuel heaters and fuel line insulation also provide a means of minimizing starting and fuel problems in cold weather when No. 2 diesel fuel is used.Fuel Related Components in Cold Weather
The 3176 electronic control module is fuel cooled. Fuel is routed from the tank, to a primary fuel filter, through the transfer pump, then through cored passages in the electronic control module housing, on to the secondary fuel filter, and finally to the injection pump.Inlet fuel temperature to the transfer pump must never exceed 149°F (65°C). Fuel temperatures in excess of this temperature reduce the life of the electronics, reduce the life of the transfer pump check valves, and reduce engine power availability.Fuel Tanks
Fuel tanks should contain some provision for draining water and sediment from the bottom of the tanks.Some fuel tanks use supply pipes that allow water