101692-3931 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016923931


 

Information injection-pump assembly

ZEXEL 101692-3931 1016923931
101692-3931 INJECTION-PUMP ASSEMBLY
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Service parts 101692-3931 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101069-9230
3. GOVERNOR 105400-6241
4. SUPPLY PUMP 105220-5610
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-4160
11. Nozzle and Holder 6206-11-3100
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105048-3060
14. NOZZLE 105017-0140
15. NOZZLE SET

Include in #1:

101692-3931 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101692-3931 1016923931


Zexel num
Bosch num
Firm num
Name
101692-3931 
 
   
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
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   1-5-3-6- 2-4
Pre-stroke mm   3.6 3.55 3.65
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-4
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   9.4
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   32.8 31.8 33.8
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   D
Rack position   9+-0.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   8 7 9
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 

Test data Ex:

Governor adjustment

Test data 101692-3931
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK CAP: R1 (3)Rack difference from N = N1 (4)Rack difference to N = N2
----------
K=17 R1=(17.5)mm N1=1250r/min N2=1250r/min
----------

Speed control lever angle

Test data 101692-3931
F:Full speed I:Idle S:Stop
----------

----------
a=(22deg)+-5deg b=32deg+-3deg c=(27deg)+-5deg

Timing setting

Test data 101692-3931
(1)Pump vertical direction (2)Position of key groove at No 1 cylinder's beginning of injection (3)Stamp aligning marks on the pump housing flange. (4)- (5)-
----------

----------
a=59deg36min+-3deg b=0deg24min+-30min




Information:

Scheduled Oil Sampling (S O S) oil analysis is the best indicator for determining what is happening inside your engine.S O S oil analysis is a diagnostic tool used to determine oil performance and component wear rates. S O S oil analysis uses a series of tests designed to identify and measure contamination such as: * soot, sulfur, etc.* degradation such as the presence of fuel, water and antifreeze in a sample of oil.* the amount of wear metals present in the oil sample.Wear metals present in the oil sample are compared to established Caterpillar norms to determine acceptability. S O S oil analysis must be performed on a continuing basis to be effective as an indicator. Intermittent sampling does not allow wear rate trend lines to be established. Obtain S O S samples at regularly scheduled intervals to monitor the condition and maintenance requirements of your engine. Each oil sample should be taken when the oil is warm and well mixed to ensure that the sample is representative of the oil in the engine crankcase.Consult with your Caterpillar dealer for complete information and assistance in establishing an S O S oil analysis program for your engine(s).S O S Oil Analysis
S O S oil analysis is composed of three basic tests: * Wear Analysis* Chemical and Physical Tests* Oil Condition Analysis Wear analysis is performed with an atomic absorption spectrophotometer to monitor component wear by identifying and measuring concentrations, in parts per million, of wear elements present in the oil. Based on known normal concentration data, maximum limits of wear elements are established. Impending failures can be identified when test results deviate from concentration levels established as acceptable, based on normal wear. Chemical and physical tests detect the presence of water, fuel and glycol (antifreeze) in the oil and determine whether or not their concentrations exceed established maximum limits. Oil condition is evaluated with infrared analysis. This test determines the presence and measures the amount of contaminants such as soot, sulfur products, oxidation, and nitration products in the oil. Infrared analysis can also assist in customizing (reducing, maintaining or extending) oil change intervals for particular conditions and applications.Infrared analysis should always be accompanied by wear element analysis and chemical and physical tests to assure accurate diagnosis. Infrared analysis must be used to determine oil change intervals. Oil analysis must include Infrared (IR) in the analysis.The test results of the oil samples will then be used as a basis for determining the oil change interval for your engine, giving you the ultimate time between oil changes without the risk of engine damage.Refer to PEDP1129, Listen To Your Oil, for information and benefits of S O S oil analysis.

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Group cross 101692-3931 ZEXEL

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