Information injection-pump assembly
ZEXEL
101603-6131
1016036131
Rating:
Cross reference number
ZEXEL
101603-6131
1016036131
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
131424-5520
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Governor side NO.1
Governor 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
-
Rack position
12.1
Pump speed
r/min
800
800
800
Each cylinder's injection qty
mm3/st.
88
85.4
90.6
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Each cylinder's injection qty
mm3/st.
10.5
9
12
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.1)
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
88
87
89
Basic
*
Fixing the lever
*
Boost pressure
kPa
61.3
61.3
Boost pressure
mmHg
460
460
Injection quantity adjustment_04
Adjusting point
C
Rack position
(R1-0.8)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
67
65
69
Fixing the lever
*
Boost pressure
kPa
28
28
28
Boost pressure
mmHg
210
210
210
Injection quantity adjustment_05
Adjusting point
I
Rack position
13.9+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
70
110
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
700
700
700
Rack position
R1-1.1
Boost pressure
kPa
22
22
22
Boost pressure
mmHg
165
165
165
Boost compensator adjustment_02
Pump speed
r/min
700
700
700
Rack position
(R1-0.8)
Boost pressure
kPa
28
26.7
29.3
Boost pressure
mmHg
210
200
220
Boost compensator adjustment_03
Pump speed
r/min
700
700
700
Rack position
R1(12.1)
Boost pressure
kPa
48
41.3
54.7
Boost pressure
mmHg
360
310
410
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1300
Advance angle
deg.
1.6
1.1
2.1
Timer adjustment_04
Pump speed
r/min
1400
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=B44 BCL=1.1+-0.1mm
----------
----------
T1=B44 BCL=1.1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18.5deg+-5deg b=(41deg)+-3deg
----------
----------
a=18.5deg+-5deg b=(41deg)+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Set the stopper bolt at speed = rated point and rack position = aa and confirm non-injection.
(2)After setting the stopper bolt, confirm non-injection at speed = cc. Rack position = bb.
(3)Rack position = approximately dd
(4)Free (at shipping)
----------
aa=(7.5)mm bb=(9)mm cc=275r/min dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg
----------
aa=(7.5)mm bb=(9)mm cc=275r/min dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg
0000001201
I:Idle
F:At operation, hold it in the full speed position.
(1)Rack position = aa, speed = bb.
----------
aa=8.4mm bb=1490r/min
----------
a=15deg+-5deg b=36deg+-3deg
----------
aa=8.4mm bb=1490r/min
----------
a=15deg+-5deg b=36deg+-3deg
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=400+-5r/min Ra=9.2mm
----------
----------
N1=400+-5r/min Ra=9.2mm
----------
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=16deg
----------
a=(1deg)
----------
aa=16deg
----------
a=(1deg)
Information:
Table 1
Part Number Container Size Volume of Finished Coolant Produced
351-9431 3.8 L (1 US gal) 50.5 L (13.3 US gal)
351-9432 20 L (5.3 US gal) 267 L (70.5 US gal)
351-9433 208 L (55 US gal) 2773 L (733 US gal)
366-2753 (1) 1000 L (264 US gal) 13333 L (3523 US gal)
(1) NACD and LACD onlyMixing Cat ELI
The recommended water for mixing with Cat ELI concentrate is distilled or deionized water. Water must meet requirements of ASTM 1193, "Type IV Reagent Water Specification". If distilled or deionized water is not available, water should meet the “Caterpillar Minimum Acceptable Water Requirements” provided in this Special Publication.To ensure a proper concentration, the preferred method is to mix Cat ELI concentrate with water. Then, add the mixed coolant to the engine cooling system. Add the proper amounts of water and Cat ELI into a clean container and mix thoroughly by manual stirring or mechanical agitation.If the preferred method cannot be performed, a Cat ELI mixture can be made by adding Cat ELI concentrate directly into engine cooling system. Add good quality water until the dilution level is approximately 7.5%. Adequate mixing is attained by operating the engine for at least 30 minutes.Appropriate mixing rates for available ELI container sizes are provided in Table 1.After the addition of water and proper mixing, the concentration of Cat ELI can be determined using the 360-0774 Digital Brix Refractometer.Changing to Cat ELI
For cooling systems previously running Cat ELC or an extended life coolant that meets Cat EC-1 requirements, drain the cooling system and flush with water. Then refill the cooling system with a mixture of 7.5% Cat ELI in water that meets the “Caterpillar Minimum Acceptable Water Requirements”.For cooling systems previously running a conventional heavy-duty coolant or a water/SCA mixture, follow the steps listed in this Special Publication, "Changing to Cat ELC". Then refill the cooling system with a mixture of 7.5% Cat ELI in water that meets the “Caterpillar Minimum Acceptable Water Requirements”.Cat ELI Maintenance
Maintenance of Cat ELI is similar to Cat ELC. A coolant sample should be submitted for S O S Level 2 Coolant Analysis after the first 500 hours of operation and then annually thereafter.Cat ELC Extender should be added at the midpoint of service life (typically 6,000 hours), or as recommended by S O S Coolant Analysis results.Analysis and interpretation of Cat ELI S O S results is similar to the analysis and interpretation of Cat ELC. There will be no glycol and glycol oxidation products, which do not apply to Cat ELI.The concentration of a sample of in-use Cat ELI taken from the cooling system can also be determined using the 360-0774 Digital Brix Refractometer.Note: Clean water is the only flushing agent that is required when Cat ELI is drained from a properly maintained cooling system.Mixing Cat ELI and Cat ELC
Since Cat ELI and Cat ELC are based on the same corrosion inhibitor technology, Cat ELI can be mixed with Cat