Information injection-pump assembly
ZEXEL
101605-9180
1016059180

Rating:
Service parts 101605-9180 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-95011
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101605-9180
1016059180
Zexel num
Bosch num
Firm num
Name
101605-9180
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
2.75
2.7
2.8
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.4
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
97
95.5
98.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
57.3
57.3
Boost pressure
mmHg
430
430
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.2
Pump speed
r/min
1115
1115
1115
Average injection quantity
mm3/st.
79.5
73.5
85.5
Fixing the rack
*
Boost pressure
kPa
57.3
57.3
Boost pressure
mmHg
430
430
Injection quantity adjustment_03
Adjusting point
C
Rack position
R1(9.7)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
79
77
81
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_04
Adjusting point
D
Rack position
6.4+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
10.5
9
12
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R1(9.7)
Boost pressure
kPa
20
17.3
22.7
Boost pressure
mmHg
150
130
170
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
10.4
Boost pressure
kPa
44
37.3
50.7
Boost pressure
mmHg
330
280
380
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)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure)
(4)Boost compensator stroke: BCL
(5)Set idle sub-spring
(6)Main spring setting
----------
K=10 L1=11.5+-0.2mm BCL=(0.7)+-0.1mm
----------
----------
K=10 L1=11.5+-0.2mm BCL=(0.7)+-0.1mm
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=3deg+-5deg b=17deg+-5deg
----------
----------
a=3deg+-5deg b=17deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
0000001101

N:Normal
B:When boosted
(1)Rack position = aa at boost pressure 0.
----------
aa=11.5+-0.2mm
----------
a=(15deg) b=(8deg)
----------
aa=11.5+-0.2mm
----------
a=(15deg) b=(8deg)
Timing setting

(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(30deg)
----------
aa=16deg
----------
a=(30deg)
Information:
Do not engage starter when flywheel is turning.Do not start engine under load.
Above 0°C (32°F)
1. Place the transmission or other power takeoff attachments in NEUTRAL. For air start systems; check the air supply before starting the engine. There must be 690 kPa (100 psi) air pressure available.2. Move governor control lever (throttle) or depress the accelerator to half engine speed position.3. Turn the battery disconnect switch (if equipped) to the ON position. 4. Push the air start knob (1) IN, or ... ... turn the start switch (2) for marine, industrial and generator set engines or ... ... turn the start switch (3) for machines (vehicles) to the START position.
Do not crank the engine for more than 30 seconds. Allow 2 minutes for the starter to cool before cranking again. If oil pressure does not rise within 15 seconds after the engine starts, stop the engine and make necessary corrections.
5. Release the start switch or air start knob when the engine starts.6. Do not apply load to the engine or increase engine speed until oil pressure and all temperature gauges reach operating temperature. Check all gauges during the warm-up period.Below 0°C (32°F)
Ether is poisonous and flammable.Do not store replacement cylinders in living areas or in the operator's compartment.Do not smoke while changing ether cylinders.Use ether only in well ventilated areas.Use it with care to avoid fires.Avoid breathing of the vapors or repeated contact of ether with skin.Do not puncture or burn cylinders.Discard cylinders in a safe place.Keep ether container away from heat, sparks, open flame, or open sunlight. It may explode.Do not store replacement cylinders at temperatures above 49°C (120°F).Do not use cylinders in environments above 93°C (200°F).
1. Depress ether switch and hold for 3 seconds, then release. For air start system; check the air supply before starting the engine. There must be 690 kPa (100 psi) air pressure available.2. Push the air start knob IN or turn the start switch for engines, or turn the start switch for machines (vehicles) to the START position.3. Begin cranking the engine, and depress ether switch and hold for 3 seconds then release. Additional injections of ether may be required to start and/or achieve low idle speed.4. Operate the engine at low speed and/or load until all systems reach operating temperatures. Check all gauges during the warmup period.
Do not use excessive starting fluid during starting or after the engine is running. Do not crank the engine for more than 30 seconds. Allow 2 minutes for the starter motor to cool before cranking again.If oil pressure does not rise within 15 seconds after the engine starts, stop the engine and make necessary corrections.
Turn the battery disconnect switch (if equipped) OFF after the engine is stopped to prevent battery discharge while starter motor is cooling.For starting below -18°C (0°F), use of optional cold weather starting aids are recommended. A coolant heater or extra battery capacity may be required.For temperatures below -23°C (-10°F), consult your Caterpillar dealer or refer to the "Cold Weather Operation
Have questions with 101605-9180?
Group cross 101605-9180 ZEXEL
Daewoo
Yanmar
Dpico
Daewoo
Yanmar
Yanmar
101605-9180
INJECTION-PUMP ASSEMBLY