Information injection-pump assembly
ZEXEL
101605-9330
1016059330
Rating:
Cross reference number
ZEXEL
101605-9330
1016059330
Zexel num
Bosch num
Firm num
Name
101605-9330
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
11.1
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
110.5
109
112
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
Injection quantity adjustment_02
Adjusting point
C
Rack position
R1(9.8)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
79.5
77.5
81.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
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(9.8)
Boost pressure
kPa
14.7
12
17.4
Boost pressure
mmHg
110
90
130
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
11.1
Boost pressure
kPa
48
42.7
53.3
Boost pressure
mmHg
360
320
400
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 (at 0 boost pressure): L1
(4)Boost compensator stroke: BCL
(5)Set idle sub-spring
(6)Main spring setting
----------
K=9 L1=11.5+-0.2mm BCL=(1.3)+-0.1mm
----------
----------
K=9 L1=11.5+-0.2mm BCL=(1.3)+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=3deg+-5deg b=18deg+-5deg
----------
----------
a=3deg+-5deg b=18deg+-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 = bb)
----------
aa=11.5+-0.2mm bb=0kPa(0mmHg)
----------
a=(15deg) b=(8deg)
----------
aa=11.5+-0.2mm bb=0kPa(0mmHg)
----------
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:
Caterpillar Diesel Truck Engines can operate effectively in cold weather, however, engine operation in cold weather is dependent on the type of fuel used and how well the fuel moves through fuel related components. The purpose of this section is to explain some of the problems and steps that can be taken to minimize fuel problems during cold weather operation when the engine area is colder than 5°C (40°F).Fuel and the Effect from Cold Weather
The two types of diesel fuel available for your truck engine are typically grades No. 1 and No. 2. Although No. 2 diesel fuel is the most commonly used fuel, No. 1 diesel fuel or a blend of No. 1 and No. 2, is the fuel that is best suited for cold weather operation.During cold weather operation, it may be necessary for you to use No. 2 diesel fuel since quantities of No. 1 diesel fuel are limited and generally are only available during the winter months and in the colder climates.There are two major differences between No. 1 and No. 2 diesel fuel. No. 1 diesel fuel has a lower cloud point and a lower pour point.The cloud point is the temperature at which a cloud or haze of wax crystals will begin to form in the fuel and cause fuel filters to plug. The pour point is the temperature which diesel fuel will begin to thicken and be more resistant to flow through fuel pumps and lines.Be aware of these fuel values when purchasing your diesel fuel and anticipate the average outside (ambient) temperature for the area your engine will be operating. Engines fueled in one climate may not operate satisfactorily if moved to another because of problems that result from cold weather. The average No. 1 diesel fuel has a lower BTU (kJ) (heat content) rating per unit volume of fuel than the average No. 2 diesel fuel. When using No. 1 diesel fuel, you may notice a drop in power and fuel efficiency, but should not experience any other operating effects.Before troubleshooting for low power or poor performance in winter months, check the type of fuel being used.The use of starting aids, engine oil pan heaters, engine coolant heaters, fuel heaters and fuel line insulation also provide a means of minimizing starting and fuel problems in cold weather when No. 2 diesel fuel is used.Fuel Related Components in Cold Weather
3176 Fuel Cooling
Fuel cooled ECMThe 3176 electronic control module is fuel cooled. Fuel is routed from the tank, to a primary fuel filter, through the transfer pump, then through cored passages in the electronic control module housing, on to the secondary fuel filter, and finally to the injection pump.Inlet fuel temperature to the transfer pump must never exceed 149°F (65°C). Fuel temperatures in
The two types of diesel fuel available for your truck engine are typically grades No. 1 and No. 2. Although No. 2 diesel fuel is the most commonly used fuel, No. 1 diesel fuel or a blend of No. 1 and No. 2, is the fuel that is best suited for cold weather operation.During cold weather operation, it may be necessary for you to use No. 2 diesel fuel since quantities of No. 1 diesel fuel are limited and generally are only available during the winter months and in the colder climates.There are two major differences between No. 1 and No. 2 diesel fuel. No. 1 diesel fuel has a lower cloud point and a lower pour point.The cloud point is the temperature at which a cloud or haze of wax crystals will begin to form in the fuel and cause fuel filters to plug. The pour point is the temperature which diesel fuel will begin to thicken and be more resistant to flow through fuel pumps and lines.Be aware of these fuel values when purchasing your diesel fuel and anticipate the average outside (ambient) temperature for the area your engine will be operating. Engines fueled in one climate may not operate satisfactorily if moved to another because of problems that result from cold weather. The average No. 1 diesel fuel has a lower BTU (kJ) (heat content) rating per unit volume of fuel than the average No. 2 diesel fuel. When using No. 1 diesel fuel, you may notice a drop in power and fuel efficiency, but should not experience any other operating effects.Before troubleshooting for low power or poor performance in winter months, check the type of fuel being used.The use of starting aids, engine oil pan heaters, engine coolant heaters, fuel heaters and fuel line insulation also provide a means of minimizing starting and fuel problems in cold weather when No. 2 diesel fuel is used.Fuel Related Components in Cold Weather
3176 Fuel Cooling
Fuel cooled ECMThe 3176 electronic control module is fuel cooled. Fuel is routed from the tank, to a primary fuel filter, through the transfer pump, then through cored passages in the electronic control module housing, on to the secondary fuel filter, and finally to the injection pump.Inlet fuel temperature to the transfer pump must never exceed 149°F (65°C). Fuel temperatures in
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101605-9330
INJECTION-PUMP ASSEMBLY