101605-9640 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016059640


 

Information injection-pump assembly

ZEXEL 101605-9640 1016059640
101605-9640 INJECTION-PUMP ASSEMBLY
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Service parts 101605-9640 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101062-9040
3. GOVERNOR 105411-1820
4. SUPPLY PUMP 105220-6410
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156639-7620
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105780-8140
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 18.1{185}
13. NOZZLE-HOLDER 105780-2080
14. NOZZLE 105780-2080
15. NOZZLE SET

Include in #1:

101605-9640 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101605-9640 1016059640


Zexel num
Bosch num
Firm num
Name
101605-9640 
 
  DPICO
INJECTION-PUMP ASSEMBLY
DB58T * Q

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   3.4 3.35 3.45
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   9.1
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   73.5 72 75
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   40 40
Boost pressure mmHg   300 300
Injection quantity adjustment_02
Adjusting point   -
Rack position   6.8+-0.5
Pump speed r/min   475 475 475
Average injection quantity mm3/st.   9.4 8.1 10.7
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   E
Rack position   -
Pump speed r/min   90 90 90
Average injection quantity mm3/st.   65 65 85
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R1-0.25
Boost pressure kPa   20 17.3 22.7
Boost pressure mmHg   150 130 170
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R1(9.1)
Boost pressure kPa   26.7 26.7 26.7
Boost pressure mmHg   200 200 200

Test data Ex:

Governor adjustment

Test data 101605-9640
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Main spring setting (6)Set idle sub-spring
----------
K=5 BCL=0.25+-0.1mm
----------

Speed control lever angle

Test data 101605-9640
F:Full speed I:Idle (1)- (2)Stopper bolt setting
----------

----------
a=1deg+-5deg b=17deg+-5deg

Stop lever angle

Test data 101605-9640
N:Normal S:Stop (1)Use the hole at R = aa (2)Speed = bb, rack position = cc (sealed at delivery)
----------
aa=40mm bb=0r/min cc=1-0.5mm
----------
a=44.5deg+-5deg b=(50deg)

Timing setting

Test data 101605-9640
(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(100deg)




Information:

Operating Cost Information
The term "Life Cycle Costs" can be defined as the sum of the individual costs experienced by an engine from the day of purchase until the day of retirement. In other words, the total Owning and Operating Costs.Owning Costs are fixed costs such as initial purchase price, interest on borrowed money, depreciation and taxes.Operating Costs are a combination of fixed and variable costs such as fuel, oil, operator expenses, road taxes, tires, chassis maintenance and repair, permits, licenses, engine maintenance and repair and downtime.The difference between revenues generated and Life Cycle Costs (total Owning and Operating Costs) is profit.Caterpillar and your Caterpillar dealer cannot guarantee that you will make a profit. However, Caterpillar and your Caterpillar dealer can provide you with a variety of services that can help you reduce the costs that impact your profits.An Engine Operating Cost Analysis is a service provided by your dealer that was developed by Caterpillar to help you reduce the Life Cycle Cost of your engine.More specifically, an Engine Operating Cost Analysis is a computerized program that examines existent and expectant oil, fuel, maintenance, minor repair, overhaul and downtime costs for the period of time you expect to own the engine. It also calculates the operating cost per mile (km), hour or day.This useful tool provides your dealer with the specific information needed to develop a customized Maintenance Management program for your operation which will minimize your engine's operating costs.Before a cost analysis can be performed, your dealer needs to gather as much information as possible about your operation. He will need to know the length of time you plan to keep your engine/vehicle, your average cost of fuel and oil as well as a variety of other ownership and cost related facts and figures.Once this information is obtained, your dealer will enter the data into an established computerized program to produce an Engine Operating Cost Analysis printout reflecting your current and projected operating costs per mile (km), hour or day.The typical printout of the Engine Operating Cost Analysis program has up to four engine scenarios which can be run at one time. The printout is divided into three major areas: * General Information* Engine Operating Information* Operating Cost SummaryGeneral Information
The General Information section contains basic user data such as name, business, location, ownership, usage per year, etc., information.Engine Operating Information
The Engine Operating Information section is divided into eight subsections that address fuel consumption, oil consumption, preventive maintenance, component repairs such as water pumps, turbochargers, air compressors, etc., before failure repairs, after failure repairs, user's revenue rate per hour and lastly, miscellaneous costs such as operator wages, insurance premiums, etc.Current and expected cost information reflected in the Engine Operating Information section is based on the data provided by you. These are the costs that affect your engine's operating cost.Operating Cost Summary
The Operating Cost Summary section is exactly what it implies, a summary. Here the total dollar expense and percentage of the total operating expense is calculated for each of

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