Information injection-pump assembly
ZEXEL
101602-4172
1016024172
ISUZU
1156016451
1156016451

Rating:
Service parts 101602-4172 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-103-2
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Cross reference number
ZEXEL
101602-4172
1016024172
ISUZU
1156016451
1156016451
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
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 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
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.7
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
50.6
49.6
51.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.5+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
7.5
6.2
8.8
Max. variation between cylinders
%
0
-14
14
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.
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Set idle sub-spring
(3)Main spring setting
(4)Rack difference between N = N1 and N = N2
----------
K=8 N1=1050r/min N2=600r/min
----------
----------
K=8 N1=1050r/min N2=600r/min
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=3deg+-5deg b=19deg+-5deg
----------
----------
a=3deg+-5deg b=19deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=46deg+-5deg
----------
----------
a=12deg+-5deg b=46deg+-5deg
Timing setting

(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=20deg
----------
a=(90deg)
----------
aa=20deg
----------
a=(90deg)
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 and former parts and listed in Table 1.
Table 1
Qty New Part Number Part Name Former Part Number
2 303-1968 Gasket 303-1968
4 346-0335 Band Clamp 346-0335
4 536-5400(1) Plate N/A
2 549-2046(2) Clean Emissions Module Ar 536-3638
536-3639
(1) The 536-5400 Plates are used to rework the 536-3638 Catalytic Converter Gp (Left-Hand) and the 536-3639 Catalytic Converter Gp (Right-Hand).
(2) The new 549-2046 Clean Emissions Module Ar is universal and can be installed on both sides of the engine.Inspect the 536-3638 Catalytic Converter Gp (Left-Hand) and the 536-3639 Catalytic Converter Gp (Right-Hand) for cracks before replacing the DOCs. If no cracks are present during inspection, the two 536-5400 Plates can be welded to the top of each DOC for support. Refer to special instruction for the complete list of parts and rework instructions.Note: If the 536-3638 Catalytic Converter Gp (Left-Hand) and the 536-3639 Catalytic Converter Gp (Right-Hand) are reworked, install the DOCs back into the original position. The DOCs are not interchangeable.The special instruction is available through the normal literature distribution system. The publication can also be found on the Caterpillar Service Information System (SIS).