101600-3010 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016003010

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101600-3010 1016003010

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Buy INJECTION-PUMP ASSEMBLY 101600-3010 zexel genuine, new aftermarket engine parts with delivery

Service parts 101600-3010 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9110

3. GOVERNOR 105404-5390

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101600-3010 as INJECTION-PUMP ASSEMBLY

Include in #2:

104761-4042 as _

Cross reference number

ZEXEL 101600-3010 1016003010

Zexel num

Bosch num

Firm num

Name

101600-3010

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

Bosch type code EF8511/9A

Nozzle 105780-0000

Bosch type code DN12SD12T

Nozzle holder 105780-2080

Bosch type code EF8511/9

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 2.5 2.45 2.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10.5

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 86 85 87

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.9+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 70 80

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder OFF *

Rack limit *

Boost compensator adjustment

Pump speed r/min 1150 1150 1150

Rack position 10.3

Boost pressure kPa 5.3 2.6 8

Boost pressure mmHg 40 20 60

Boost compensator adjustment_02

Pump speed r/min 1150 1150 1150

Rack position 10.5

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Adjust the secondary timing before adjusting the governor. (4)RACK LIMIT (5)The torque control spring must does not have a set force. (6)When hydraulic cylinder ON: P1 (7)Boost compensator stroke: BCL (8)Rack difference between N = N1 and N = N2
----------
K=17 P1=((392)kPa,(4)kgf/cm2) BCL=0.2+-0.1mm N1=1150r/min N2=625r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(21deg)+-5deg b=(25deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=18deg bb=0deg
----------
a=54deg54min+-3deg b=9deg+-30min

Information:

Introduction
There have been instances of issues with DEF pumps. After analysis, the cause of the issues has been found as contamination with hydrocarbons.Note: Diesel fuel is an example of a hydrocarbon.The DEF filter is equipped with a compensator located in the center of the filter assembly. If the compensator comes into contact with hydrocarbons, the compensator will swell and is designed to block the filter assembly and protect the DEF pump.Solution
The following procedure is designed to diagnose if the DEF pump has been contaminated with hydrocarbons.
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Ensure that the engine is stopped before any servicing or repair is performed. The Diesel Exhaust Fluid (DEF) system must have completed a proper shutdown. Service on the DEF pump prior to completion of a proper shutdown can result in DEF spray and spillage.
Do not turn off the battery disconnect switch until the indicator lamp has turned off. If the switch is turned off when the indicator lamp is illuminated, the Diesel Exhaust Fluid (DEF) system may not shut down properly. If the DEF system does not shut down properly, DEF could freeze and damage the pump and lines.
Care must be taken to ensure that fluids are contained during performance of inspection, maintenance, testing, adjusting, and repair of the product. Be prepared to collect the fluid with suitable containers before opening any compartment or disassembling any component containing fluids.Refer to Special Publication, NENG2500, "Cat Dealer Service Tool Catalog" or refer to Special Publication, PECJ0003, "Cat Shop Supplies and Tools Catalog" for tools and supplies suitable to collect and contain fluids on Cat products.Dispose of all fluids according to local regulations and mandates.
Note: Clean water should be used to wash spilled DEF off machine components and surfaces.Note: Wear gloves when handling the DEF filter.
Illustration 1 g06278274
(1) Protective cover
Remove protective cover (1).
Illustration 2 g06278289
(2) DEF filter cap
Use a suitable tool to remove DEF filter cap (2).
Illustration 3 g06278325
(3) Compensator
With the filter installed in the DEF pump, carefully remove compensator (3).
Illustration 4 g06614423
(A) 85 mm (3.3 inch)
(B) 17 mm (0.7 inch)
Check the measurements of compensator (3). Check if the measurements are greater than specified in Illustration 4. This condition indicates that the DEF pump is contaminated with hydrocarbons.
If the measurements indicate contamination, replace the DEF pump filter. Refer to Operation and Maintenance Manual, Diesel Exhaust Fluid Filter - Replace.Flush the DEF tank. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Tank - Flush.
If the measurements are within the specification, continue to follow the appropriate troubleshooting procedure to determine if the DEF pump has a fault.