101601-5820 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015820

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5820 1016015820

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Service parts 101601-5820 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9931

3. GOVERNOR 105921-5320

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0670

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4292

11. Nozzle and Holder 23600-1593A

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105025-0490

15. NOZZLE SET

Include in #1:

101601-5820 as INJECTION-PUMP ASSEMBLY

104303-5280 as _

Cross reference number

ZEXEL 101601-5820 1016015820

Zexel num

Bosch num

Firm num

Name

101601-5820

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 131424-5720

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 1-4-2-6- 3-5

Pre-stroke mm 3.1 3.07 3.13

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 9.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 58.5 56.5 60.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 6.8 5.3 8.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.4)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 58.5 57.5 59.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 67.3 63.3 71.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.35

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 37.9 33.9 41.9

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.25

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 67.8 63.8 71.8

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.1

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 32.9 28.9 36.9

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 99 99 109

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1000+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 3.5 3.2 3.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=F94
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=32deg+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Stopper bolt setting (2)(Apply red paint after setting.) (3)Engine normal
----------

----------
a=40deg+-5deg b=40deg+-5deg c=35deg+-2deg

0000001501 TAMPER PROOF

1. Method for setting tamperproof proofing (1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to Ra. (2)At pump speed N1, push in the screw (A) until the rack position is Rb. (3)Temporarily caulk using the tip of a screwdriver (4)Confirm that the rack at that time is at Rc. (5)Lock using setscrew (B). (Tightening torque = T) (6)Next, coat (C) with adhesive and then pressfit. (7)Then, readjust the full rack position using the load lever.
----------
N1=1500r/min Ra=(0.4)mm Rb=R1(9.4)+0.5mm Rc=R1(9.4)+0.5mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

For additional torque specifications, not included in this section, refer to Torque Specifications, SENR3130 available from your Caterpillar dealer.Torque for Standard Fasteners
The following charts give general torques for bolts, nuts and taperlock studs of SAE Grade 5 or better quality.
Torque for Bolts, Nuts and 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
Be very careful never to mix metric with U.S. 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.). The following chart gives general torques for bolts and nuts with Metric Threads of SAE Grade 8.8 or better quality.
Metric hardware must be replaced with metric hardware. Check parts manual for proper replacement.Torques for Bolts, Nuts and Taperlock Studs 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 5.7 N m (50 lb in).* To allow for equal expansion and contraction, install clamps at 10.2 N m (90 lb in).* To allow for maximum contraction, install clamps at 14.1 N m (125 lb in).