Information injection-pump assembly
ZEXEL
101602-2010
1016022010
HINO
220201162A
220201162a
Rating:
Service parts 101602-2010 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1171
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101602-2010
1016022010
HINO
220201162A
220201162a
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
Overflow valve
134424-0620
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
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
4.85
4.8
4.9
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
7.9
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
80.5
78.9
82.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
4.3+-0.5
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
9.5
8
11
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
14+-0.5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
166
156
176
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Set idle sub-spring
----------
K=10
----------
----------
K=10
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=0deg+-5deg b=25deg+-5deg
----------
----------
a=0deg+-5deg b=25deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
a=27deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Table 1
S O S Oil Analysis Guidelines
Test Parameter Guideline
Oxidation (1)
Soot (1)
Sulfation (1)
Wear Metals Trend Analysis and Cat Wear Table (1) norms
Water 0.5% maximum
Glycol 0%
Fuel Dilution Based on viscosity (1) and GC (2) fuel dilution in excess of 4%
Viscosity "ASTM D445" measured at 100° C (212° F) +/-3 centistokes (cSt) change from new oil viscosity.
( 1 ) Acceptable values for these parameters are proprietary to the S O S oil analysis program.
( 2 ) Gas ChromatographConsult your Caterpillar dealer for complete information and assistance about the S O S oil analysis program.Obtaining S O S Oil Samples
Before you obtain an S O S oil sample, operate the engine until the oil is warm and the oil is well circulated. Then obtain the S O S oil sample.In order to obtain a good oil sample, do not take the oil sample from the drain stream. The drain stream method can allow a stream of dirty oil from the bottom of the compartment to contaminate the sample. Likewise, never dip an oil sample from an oil container or pour a sample from a used filter.There are two acceptable ways to obtain S O S oil samples. The following methods are listed in the order that is preferred:
Use an in-line sampling valve on the pressurized oil manifold.
Use a sampling gun (vacuum pump) that is inserted into the sump.Use of the in-line sampling valve is the preferred method. This method provides samples that are less likely to be contaminated. In order to obtain an oil sample from the engine, it may be necessary to increase the engine's speed. Normally, the oil sample is taken at low idle. If the flow rate is too low, increase engine speed to high idle in order to obtain the oil sample.
Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples.A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken.Always use a separate pump for oil sampling and a separate pump for coolant sampling.Failure to do so may cause a false analysis which could lead to customer and dealer concerns.
Oil Sampling Interval
Take the oil samples as close as possible to the standard intervals. In order to receive the full value from S O S oil analysis, you must establish a consistent trend of data. In order to establish pertinent history of data, perform consistent oil samplings that are evenly spaced.
Table 2
Compartment Engine
Recommended Sampling Interval
24140 kilometers (15000 miles)
(1) (2)
Sampling Valve Yes
Oil Type DEO, DEO-ULS
Recommended Oil Change Interval (3)
( 1 ) Under certain conditions, the Caterpillar dealer or the Operation and Maintenance Manual may allow a longer