101607-9280 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016079280

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-9280 1016079280

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Service parts 101607-9280 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5340

3. GOVERNOR 105921-7890

4. SUPPLY PUMP

105220-7010

5. AUTOM. ADVANCE MECHANIS 105672-0380

6. COUPLING PLATE 105662-1370

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4113

11. Nozzle and Holder 16600-Z5665

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105031-4650

14. NOZZLE 105025-1020

15. NOZZLE SET

Include in #1:

101607-9280 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-5300 as _

Cross reference number

ZEXEL 101607-9280 1016079280

Zexel num

Bosch num

Firm num

Name

101607-9280

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 134424-1520

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 3.4 3.35 3.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.9

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 72.5 70.9 74.1

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 9.5+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.5 7.7 11.3

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(11.9)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 72.5 71.5 73.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(11.9)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 84 80 88

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 80 90

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1200--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 6.5 6.2 6.8

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=K25
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=20.5deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=40deg+-5deg

0000001501 RACK SENSOR

R:Rack position (mm) V:Voltage (V) After installing the rack sensor, confirm the output value (VR).
----------
N1=800r/min Ra=R1(11.9)mm VR=2.5+-0.01V
----------

Timing setting

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

----------
a=(60deg)

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.The new 593-6000 replaces the former 580-8475 Monitor Software Gp.The 580-8475 Monitor Software Gp is canceled.Any DCU or Remote Panels (410E) with a Linux kernel with build date of December 2017or older are applicable for this update. The listed Kernel version in the "version screen" is a date on the format YYMMDD. For example, "171207" should be read as 2017-December-07th.The new software is available in the form of a flashfile through the Caterpillar Service Information System (SIS). A newer part number may be available. SIS web only displays the latest available flashfile.Installation Instructions
Using the PC, copy the file called amupdate.img to the USB stick. Make sure that the file is located directly on the USB stick and not saved in any directory on the USB stick.
Take note of the current Kernel version of the unit (if possible).
Disconnect the supply power to the unit to be upgraded.
Insert the USB stick at the back of the unit.
Reconnect the supply power to the unit and observe brief block of text message on the display, as the new kernel is being uploaded and installed. (This message is only shown for a few seconds.)
Wait for the unit to start up fully. Dismiss the USB Storage form, if shown, and remove the USB stick from the unit.
Check the Kernel version and verify that the Kernel version is "191022".