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104747-7110 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047477110 6273711140


 

Information injection-pump assembly

ZEXEL 104747-7110 1047477110
KOMATSU 6273711140 6273711140
104747-7110 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 104747-7110 1047477110
KOMATSU 6273711140 6273711140


Zexel num
Bosch num
Firm num
Name
104747-7110 
 
6273711140  KOMATSU
INJECTION-PUMP ASSEMBLY
S4D95LWE-

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   500 500 500
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   56.1 55.6 56.6
Basic   *
Oil temperature degC   48 46 50
Remarks
NA  
Injection timing adjustment_02
Pump speed r/min   800 800 800
Boost pressure kPa   18.7 17.4 20
Boost pressure mmHg   140 130 150
Average injection quantity mm3/st.   64.1 63.6 64.6
Basic   *
Oil temperature degC   50 48 52
Remarks
CBS  
Injection timing adjustment_03
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.   66.8 66.3 67.3
Difference in delivery mm3/st.   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.   56.1 55.1 57.1
Basic   *
Oil temperature degC   48 46 50
Remarks
NA  
Injection timing adjustment_05
Pump speed r/min   800 800 800
Boost pressure kPa   18.7 17.4 20
Boost pressure mmHg   140 130 150
Average injection quantity mm3/st.   64.1 63.1 65.1
Basic   *
Oil temperature degC   50 48 52
Remarks
CBS  
Injection timing adjustment_06
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.   66.8 65.8 67.8
Difference in delivery mm3/st.   5.5
Basic   *
Oil temperature degC   50 48 52
Remarks
Full  
Injection timing adjustment_07
Pump speed r/min   1300 1300 1300
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Average injection quantity mm3/st.   58 53.5 62.5
Oil temperature degC   50 48 52
Injection quantity adjustment
Pump speed r/min   1425 1425 1425
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Average injection quantity mm3/st.   31.3 28.3 34.3
Difference in delivery mm3/st.   9
Basic   *
Oil temperature degC   50 48 52
Injection quantity adjustment_02
Pump speed r/min   1600 1600 1600
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Average injection quantity mm3/st.   3
Oil temperature degC   50 48 52
Injection quantity adjustment_03
Pump speed r/min   1425 1425 1425
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Average injection quantity mm3/st.   31.3 26.8 35.8
Basic   *
Oil temperature degC   50 48 52
Governor adjustment
Pump speed r/min   400 400 400
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   16.1 14.1 18.1
Difference in delivery mm3/st.   3
Basic   *
Oil temperature degC   48 46 50
Governor adjustment_02
Pump speed r/min   350 350 350
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   30.5 23.5 37.5
Oil temperature degC   48 46 50
Governor adjustment_03
Pump speed r/min   400 400 400
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   16.1 13.6 18.6
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.   80 75 85
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.   80 75 85
Oil temperature degC   48 46 50
Remarks
IDLE  
Speed control lever angle
Pump speed r/min   400 400 400
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   1300 1300 1300
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Overflow quantity cm3/min   430 300 560
Oil temperature degC   50 48 52
Stop lever angle
Pump speed r/min   1300 1300 1300
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
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
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
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   900 900 900
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Pressure kPa   441 392 490
Pressure kgf/cm2   4.5 4 5
Oil temperature degC   50 48 52
Stop lever angle_04
Pump speed r/min   1100 1100 1100
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Pressure kPa   500 451 549
Pressure kgf/cm2   5.1 4.6 5.6
Oil temperature degC   50 48 52
Stop lever angle_05
Pump speed r/min   1300 1300 1300
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
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
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Timer stroke mm   2.7 2.5 2.9
Basic   *
Oil temperature degC   50 48 52
_02
Pump speed r/min   800 800 800
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Timer stroke mm   0.5
Oil temperature degC   50 48 52
_03
Pump speed r/min   1300 1300 1300
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Timer stroke mm   2.7 2.4 3
Basic   *
Oil temperature degC   50 48 52
0000001201
Max. applied voltage V   8 8 8
Test voltage V   13 12 14
0000001401
Pump speed r/min   1300 1300 1300
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Average injection quantity mm3/st.   46 45 47
Timer stroke TA mm   2.1 1.9 2.3
Timer stroke variation dT mm   0.6 0.6 0.6
Basic   *
Oil temperature degC   50 48 52
_02
Pump speed r/min   1300 1300 1300
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Average injection quantity mm3/st.   46 44.5 47.5
Timer stroke TA mm   2.1 1.8 2.4
Timer stroke variation dT mm   0.6 0.6 0.6
Basic   *
Oil temperature degC   50 48 52
_03
Pump speed r/min   1300 1300 1300
Boost pressure kPa   40 38.7 41.3
Boost pressure mmHg   300 290 310
Average injection quantity mm3/st.   38 36 40
Timer stroke TA mm   1.2 0.7 1.7
Timer stroke variation dT mm   1.5 1.5 1.5
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.   29 24 34

Test data Ex:

0000001601 BCS ADJUSTMENT

Test data 104747-7110
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=18.7kPa(140mmHg) 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

Test data 104747-7110
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 TAMPER PROOF

Test data 104747-7110
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

0000002001 STARTING I/Q ADJUSTMENT

Test data 104747-7110
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




Information:

Caterpillar's Scheduled Oil Sampling (S O S) is the best indicator for determining what is happening inside your engine.S O S is a diagnostic tool used to determine oil performance and component wear rates with a series of tests designed to identify and measure contamination such as soot, sulfur, etc. and degradation such as the presence of fuel, water and antifreeze in a sample of oil.The tests also determine the amount of wear metals present in the oil sample, which is compared to established Caterpillar norms to determine acceptability. To be effective as an indicator, S O S must be performed on a continuing basis. Intermittent sampling will not allow wear rate trend lines to be established.Obtain S O S samples at regularly scheduled intervals to monitor the condition and maintenance requirements of your engine. Each oil sample should be taken when the oil is warm and well mixed to ensure that the sample is representative of the oil in the engine crankcase and oil pan.Consult your Caterpillar dealer for complete information and assistance in establishing an S O S program for your engine(s). S O S AnalysisS O S is composed of three basic tests:* Wear Analysis* Chemical and Physical Tests* Oil Condition Analysis Wear Analysis is performed with an atomic absorption spectrophotometer to monitor component wear by identifying and measuring concentrations, in parts per million, of wear elements present in the oil. Based on known normal concentration data, maximum limits of wear elements are established. Impending failures can be identified when test results deviate from concentration levels established as acceptable, based on normal wear. Chemical and Physical Tests detect the presence of water, fuel and glycol (antifreeze) in the oil and determine whether or not their concentrations exceed established maximum limits. Oil Condition Analysis is evaluated with infrared analysis (IR). This test determines the presence and measures the amount of contaminants such as soot, sulfur products, oxidation, and nitration products in the oil. Infrared analysis can also assist in customizing (reducing, maintaining or extending) oil change intervals for particular conditions and applications.Infrared analysis should always be accompanied by wear element analysis and chemical and physical tests to assure accurate diagnosis. Infrared analysis must be used to determine oil change intervals. S O S must include Infrared (IR) in the analysis.The test results of the oil samples will then be used as a basis for determining the oil change interval for your engine, giving you the ultimate time between oil changes without the risk of engine damage.Refer to Caterpillar pamphlet Scheduled Oil Sampling, form PEDP7105 for information and benefits of S O S. Obtain SampleEach oil sample should be taken when the oil is warm and well mixed to ensure that the sample is representative of the oil in the crankcase.There are two methods recommended to obtain S O S samples from the 3176 engine crankcase. * Use the sampling valve, if installed on the engine, for samples.* Use a sampling gun inserted into the sump. Refer

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