101600-3020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016003020

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101600-3020 1016003020

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Buy INJECTION-PUMP ASSEMBLY 101600-3020 zexel genuine, new aftermarket engine parts with delivery

Service parts 101600-3020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-9111

3. GOVERNOR 105404-5570

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:

101600-3020 as INJECTION-PUMP ASSEMBLY

Include in #2:

104761-4112 as _

Cross reference number

ZEXEL 101600-3020 1016003020

Zexel num

Bosch num

Firm num

Name

101600-3020

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 131424-3420

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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 11

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 82.5 81.5 83.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.6+-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 *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 75 75 85

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Adjust the secondary timing before adjusting the governor. (4)RACK LIMIT (5)Rack difference between N = N1 and N = N2 (6)Rack difference between N = N3 and N = N4
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K=10 N1=1250r/min N2=800r/min N3=1250r/min N4=550r/min
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Speed control lever angle

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

----------
a=16deg+-5deg b=33deg+-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:

Illustration 3 g01783679
Top view of machine
Illustration 4 g01783683
Right side view of machine (A) Hood and guard group (B) Lines group (Air) (C) Air cleaner
Illustration 5 g01783717
Front view of machineInstallation Procedure
The installation procedure that follows is specific for the listed machine.Diesel Particulate Filter Installation
Illustration 6 g01783522
(2) 331-8935 Bracket (12) 5P-8245 Hard Washer (13) 6V-8149 Nut (14) 8F-6437 Washer (15) 8T-4956 Bolt
Place two new 331-8935 Brackets (2) parallel to each other on top of the hood. Secure the brackets to the hood using four new 8F-6437 Washers (14), four new 5P-8245 Hard Washers (12), four new 6V-8149 Nuts (13), and four new 8T-4956 Bolts (15). Refer to Illustration 6.
Illustration 7 g01783527
(5) 295-3044 Exhaust Support Gp
Install the two lower halves of the new 295-3044 Exhaust Support Gp (5) onto two brackets (2) using four new washers (14) and four new bolts (15). Refer to Illustration 7.
Illustration 8 g01783553
(1) 331-8928 Diesel Particulate Filter Gp (5a) Bolt (5b) Hard washer (5c) Weld nut
Place the new 331-8928 Diesel Particulate Filter Gp (1) onto the two lower halves of exhaust support group (5). The weight of the diesel particulate filter group is approximately 44 kg (97 lb). Refer to Illustration 8.
Install the two upper halves of exhaust support group (5) onto the bottom halves of the exhaust support group using four 5P-8245 Hard Washers (5b), four 8T-3597 Weld Nuts (5c), and four 6V-3823 Bolt (5a). Refer to Illustration 8.
Illustration 9 g01783556
(a) Outlet module tube (9) 174-5414 Clamp (11) 255-2899 Tail Pipe As
Connect the new 255-2899 Tail Pipe As (11) to outlet module tube (a) of diesel particulate filter group (1) using a new 174-5414 Clamp (9). Refer to Illustration 9.
Illustration 10 g01783574
(b) Inlet module tube (3) 331-8931 Filter Tube As (7) 241-6170 Plug (8) 8T-6765 Pipe Plug (10) 209-4589 Clamp
Connect the new 331-8931 Filter Tube As (3) to inlet module tube (b) of diesel particulate filter group (1) using one new 209-4589 Clamp (10). Refer to Illustration 10.
Install the new 8T-6765 Pipe Plug (8) and 241-6170 Plug (7) onto the two respective bosses provided on filter tube assembly (3). Refer to Illustration 10.
Illustration 11 g01783595
(6) 270-0112 Bellows
Connect the new 270-0112 Bellows (6) to filter tube assembly (3) using one new clamp (10). Refer to Illustration 11.
Illustration 12 g01783578
(4) 331-8934 Filter Tube
Connect the new 331-8934 Filter Tube (4) to bellows (6) using one new clamp (10). Refer to Illustration 12.
Connect the other end of filter tube (4) to the air lines group using the clamp that is used to connect the muffler tube to the air lines group.Exhaust Monitor Installation
Refer to Special Instruction, REHS5606, "Installation and Operation of the Caterpillar Diesel Particulate Filter (DPF) and the Diagnostic Module for Non-Road Machine Applications (Non-California Applications)" for information regarding the installation and the operation of the exhaust monitor.The exhaust monitor is a device designed to monitor