Information injection-pump assembly
ZEXEL
101606-0210
1016060210
Rating:
Cross reference number
ZEXEL
101606-0210
1016060210
Zexel num
Bosch num
Firm num
Name
101606-0210
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
105780-8260
Bosch type code
9 430 610 133
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
18
Opening pressure
kgf/cm2
184
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-8620
Overflow valve opening pressure
kPa
206
172
240
Overflow valve opening pressure
kgf/cm2
2.1
1.75
2.45
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.8
3.75
3.85
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 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
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
14.1
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
126
124.4
127.6
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
15.5
14.2
16.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(14.1)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
126
125
127
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
(R1+1.55
)+0.05-0
.15
Pump speed
r/min
1425
1425
1425
Average injection quantity
mm3/st.
137.5
134.3
140.7
Fixing the lever
*
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.
----------
T1=N91
----------
----------
T1=N91
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C2=(8)deg t1=2--sec. t2=2--sec.
----------
N1=1300++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N2=800r/min C2=(8)deg t1=2--sec. t2=2--sec.
----------
N1=1300++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
(2)Use the pin at R = aa
(3)Viewed from feed pump side.
----------
aa=35mm
----------
a=10deg+-5deg b=40.5deg+-3deg
----------
aa=35mm
----------
a=10deg+-5deg b=40.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR
Rack sensor adjustment
1. Flange type rack sensor (rack sensor adjustment -5*20)
(1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures.
(2)Mount the rack sensor main body to the pump main body.
(3)Fix the pump lever at full.
(4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist.
(5)Move the pump lever two or three times.
(6)Set again to full.
(7)Confirm that the amplifier output voltage is Vist.
(8)Fix the caution plate to the upper part of the rack sensor.
(For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.)
(9)Apply red paint to the rack sensor mounting bolts (2 places).
----------
V1=5+-0.01V N1=850r/min Ra=R1(14.1)mm Vist=3.55+-0.28V
----------
----------
V1=5+-0.01V N1=850r/min Ra=R1(14.1)mm Vist=3.55+-0.28V
----------
Timing setting
(1)Pump vertical direction
(2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=6deg
----------
a=(160deg)
----------
aa=6deg
----------
a=(160deg)
Information:
Engine Lifting
When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90°. Eyebolts and brackets should never be bent and should only be loaded in tension.
Use a hoist to remove heavy components. Lift the engine by using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other, and as near perpendicular as possible to the top of the object being lifted.Some removals require the use of lifting fixtures to obtain proper balance and to provide safe handling. To remove the engine, use the two lifting eyes on the engine.Lifting eyes are designed for the arrangement as sold. Alterations to lifting eyes and/or arrangement weight make the lifting devices obsolete.If you make alterations, you are responsible for providing adequate lifting devices.Engine Storage
If the engine will not be or has not been started for several weeks, the lubricating oil will drain from the cylinder walls and piston rings.If an engine remains out of service and its use is not immediately planned, special precautions should be taken. Rust can form on the cylinder liner surface, which will increase engine wear and may result in shorter engine life. To prevent this problem from becoming excessive, be sure all lubrication recommendations mentioned in the Maintenance Schedule are completed.If freezing temperatures are expected, check the cooling system for adequate protection against freezing. A 50/50 solution of Caterpillar (permanent-type) Antifreeze and approved water will give protection to -20°F (-29°C).If it will be impossible to start the engine periodically, consult your Caterpillar dealer for instructions to prepare your engine for longer storage periods.Refer to Storage Procedures For Caterpillar Products, form SEHS9031 for more detailed information on engine storage.
When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90°. Eyebolts and brackets should never be bent and should only be loaded in tension.
Use a hoist to remove heavy components. Lift the engine by using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other, and as near perpendicular as possible to the top of the object being lifted.Some removals require the use of lifting fixtures to obtain proper balance and to provide safe handling. To remove the engine, use the two lifting eyes on the engine.Lifting eyes are designed for the arrangement as sold. Alterations to lifting eyes and/or arrangement weight make the lifting devices obsolete.If you make alterations, you are responsible for providing adequate lifting devices.Engine Storage
If the engine will not be or has not been started for several weeks, the lubricating oil will drain from the cylinder walls and piston rings.If an engine remains out of service and its use is not immediately planned, special precautions should be taken. Rust can form on the cylinder liner surface, which will increase engine wear and may result in shorter engine life. To prevent this problem from becoming excessive, be sure all lubrication recommendations mentioned in the Maintenance Schedule are completed.If freezing temperatures are expected, check the cooling system for adequate protection against freezing. A 50/50 solution of Caterpillar (permanent-type) Antifreeze and approved water will give protection to -20°F (-29°C).If it will be impossible to start the engine periodically, consult your Caterpillar dealer for instructions to prepare your engine for longer storage periods.Refer to Storage Procedures For Caterpillar Products, form SEHS9031 for more detailed information on engine storage.
Have questions with 101606-0210?
Group cross 101606-0210 ZEXEL
Isuzu
101606-0210
INJECTION-PUMP ASSEMBLY