101602-2322 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016022322


 

Information injection-pump assembly

ZEXEL 101602-2322 1016022322
101602-2322 INJECTION-PUMP ASSEMBLY
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Service parts 101602-2322 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-3431
3. GOVERNOR 105400-5211
4. SUPPLY PUMP 105210-4351
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105661-0410
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-5490
11. Nozzle and Holder 23600-1830A
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105030-4060
14. NOZZLE 105015-7180
15. NOZZLE SET

Include in #1:

101602-2322 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101602-2322 1016022322


Zexel num
Bosch num
Firm num
Name
101602-2322 
 
   
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   134424-0920
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   4 3.95 4.05
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   A
Rack position   9.3
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   86.5 85.5 87.5
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   6+-0.5
Pump speed r/min   410 410 410
Average injection quantity mm3/st.   10 9 11
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   C
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   130 130 140
Fixing the lever   *
Rack limit   *

Test data Ex:

Governor adjustment

Test data 101602-2322
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting
----------
K=6
----------

Speed control lever angle

Test data 101602-2322
F:Full speed I:Idle S:Stop (1)Set the stopper bolt at delivery
----------

----------
a=(16deg)+-5deg b=(16deg)+-5deg c=(16deg)+-5deg

Stop lever angle

Test data 101602-2322
N:Pump normal S:Stop the pump. (1)Normal (2)Rack position aa or less, pump speed bb
----------
aa=5mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

Test data 101602-2322
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

In the New Systems, Refilled Systems, and converted systemsEvery year: add to it hours: ever year or every 2000 hours, whichever comes first.When referring to the Service Life in table 1, use the interval that occurs first. These coolant change intervals are only achievable with annual S O S Services Level 2 coolant sampling analysis.Refer to the engine Operation and Maintenance Manual for the correct interval for replacement of the cooling system water temperature regulator.Note: For engines that require a maximum of 20% glycol, make sure that the amount of additive in the final mix is appropriate. Example of mixing a 20% glycol solution is given in Table 3.
Table 3
Example of Mixing Up a 20% Glycol Coolant (1)
Total Volume of the Cooling System Add the Following:
ELC Concentrate ELI Concentrate Water
10 Gallons 2 Gallons 0.5 Gallons 7.5 Gallons
(1) Volumes can also be in liters as long as all the volume units are consistentExtended life coolants require the one time maintenance addition of an extender at coolant service mid-life. For commercial coolants, do NOT use an extender with a coolant unless the extender has been approved by the coolant manufacturer for use with the coolant. The coolant manufacturer is responsible to ensure compatibility and acceptable performance. Failure to follow these recommendations can result in shortened cooling system component life.Conventional coolants require the maintenance addition of SCA throughout the expected life. For commercial coolants, do NOT use an SCA unless approved by the coolant supplier for use with the coolant. The coolant manufacturer is responsible to ensure compatibility and acceptable performance."ASTM D6210" require coolants that are properly dosed with SCA and that are in a properly maintained cooling system in normal service to be suitable for use for a maximum of 2 years. The suitability for use requirement is the direct responsibility of the coolant manufacturer and SCA manufacturer. Consult with the coolant and/or SCA manufacturer concerning the suitability of the products for use in a given application.Cat DEAC is fully formulated and does not require a treatment with an SCA at the initial fill.A commercial heavy-duty coolant/antifreeze that meets the "ASTM D6210"specification does not require a treatment with an SCA at the initial fill.Commercial Heavy Duty coolants that meet only "ASTM D4985" specification are not recommended for Caterpillar applications. These coolants may not provide the performance characteristics needed for heavy duty applications. Cat coolants and the coolants detailed in Table 1 and in this Chapter are formulated to offer the required performance in Cat engines. Refer to Table 1 for Cat coolants recommendations.Cat ELC, Cat ELI, Cat DEAC, Cat Extender, and Cat SCA are available in several container sizes. The availability of part numbers will vary by the region. Consult your Cat dealer.In stationary and marine engine applications that do not require protection from boiling or freezing, except as noted in Table 2, Cat ELI in water or SCA and water are acceptable.

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