101608-1571 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081571

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-1571 1016081571

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Cross reference number

ZEXEL 101608-1571 1016081571

Zexel num

Bosch num

Firm num

Name

101608-1571

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 105780-8260

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

Overflow valve 131424-8420

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Governor 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 -

Rack position 11.6

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 90.5 87.8 93.2

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 310 310 310

Each cylinder's injection qty mm3/st. 10.8 9.2 12.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 90.5 89.5 91.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.4

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 90 86 94

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.3

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 90 86 94

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 155 175

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1450

Advance angle deg. 5 4.5 5.5

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=M16
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=33deg+-5deg b=(42deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)After setting the stopper bolt at the speed lever's full position, confirm that there is no injection at pump speed aa and rack position bb. (2)After setting the stopper bolt at the speed lever's idle position, confirm that there is no injection at pump speed cc and rack position dd (non-injection rack position).
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8)mm
----------
a=25deg+-5deg b=(25deg)+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(1deg)

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".