Information injection-pump assembly
ZEXEL
101631-9571
1016319571
Rating:
Service parts 101631-9571 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-20053
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Include in #1:
101631-9571
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
101631-9571
1016319571
Zexel num
Bosch num
Firm num
Name
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
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
2.15
2.1
2.2
Rack position
R=11.6
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
11.6
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
32.5
31.5
33.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
8.1+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
7.5
6.4
8.6
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
550
Advance angle
deg.
0.7
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
2.2
1.7
2.7
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
4.4
3.9
4.9
Timer adjustment_05
Pump speed
r/min
1900
Advance angle
deg.
7.5
7
8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
P:Negative pressure
(1)Pneumatic governor
(2)Mechanical governor
(3)Acting negative pressure: P1
(4)RACK LIMIT: RAL
(5)Beginning of idle sub spring operation: L1
----------
RAL=16mm L1=8+0.3mm
----------
----------
RAL=16mm L1=8+0.3mm
----------
Speed control lever angle
B:When boosted
N:Normal
S:Stop
(1)Rack position = aa
(2)Rack position bb
----------
aa=0.5mm bb=16mm
----------
a=23.5deg+-3deg b=8.5deg+-5deg c=2deg+-5deg
----------
aa=0.5mm bb=16mm
----------
a=23.5deg+-3deg b=8.5deg+-5deg c=2deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(140deg)
----------
----------
a=(140deg)
Information:
PARTS NEEDED
Qty
Part Number Description
1 4742607 VALVE-BALL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 1% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Replace the existing DEF valve assembly with a new 474-2607 Ball Valve. Refer to Image1.
Note: The 6S-8620 Clamps are reusable. Tighten the clamp to a specified torque of 1.4 +/- 0.3 N.m (12.4 +/- 2.7 lb-in).
Note: Insert the hose up to the root of the valve tube.
Note: Place the clamp on the straight portion of the hose by the bead of the valve tube.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3001-6000 hrs,
25-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 3.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.