Information injection-pump assembly
ZEXEL
101601-4731
1016014731
ISUZU
1156007671
1156007671
Rating:
Cross reference number
ZEXEL
101601-4731
1016014731
ISUZU
1156007671
1156007671
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
131424-0220
Overflow valve opening pressure
kPa
147
113
181
Overflow valve opening pressure
kgf/cm2
1.5
1.15
1.85
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
3.7
3.65
3.75
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
11.2
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
111.5
109.5
113.5
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
11.6
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
115
114
116
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
8.6+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
11.5
9.2
13.8
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
14.2+-0.
5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
140
140
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
925
Advance angle
deg.
0.3
Timer adjustment_02
Pump speed
r/min
975
Advance angle
deg.
1.4
0.1
1.4
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
2.4
1.9
2.9
Timer adjustment_04
Pump speed
r/min
1150
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Excess fuel setting for starting: SXL
----------
DL=6.5+-0.5mm SXL=12.4+-0.1mm
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----------
DL=6.5+-0.5mm SXL=12.4+-0.1mm
----------
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=22deg+-3deg b=55deg+-5deg
----------
----------
a=22deg+-3deg b=55deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=35.5deg+-5deg b=71deg+-5deg
----------
----------
a=35.5deg+-5deg b=71deg+-5deg
Information:
Exhaust Smoke Can Be Seen While Starting
Possible Causes/Corrections
Cold Outside Temperatures/It can be necessary to use starting aids, or to heat engine oil or coolant at temperatures below -12° C (10° F). Air in Fuel System/With air in the fuel system, the engine will normally be difficult to start, run rough and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air can not be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak. Low Quality Fuel/Remove a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, remove fuel from the tank until it is free of water and fill with a good quality fuel. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines.Change the fuel filter and "prime" (remove the air and/or low quality fuel from the fuel system) the fuel system with the fuel priming pump. If there is no water in the fuel, prime and start the engine by using an outside source of fuel. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel. Prime the fuel system if necessary. Low Fuel Pressure/Change the primary and secondary fuel filters and check to make sure the fuel lines are not plugged or damaged. If the filters or lines are not the cause, a repair or replacement of the fuel transfer pump is needed. Fuel Injection Timing Not Correct/Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Valve Adjustment Not Correct/Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in.) and exhaust valve clearance is 0.64 mm (.025 in.). Bad Fuel Nozzle(s)/Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual. Low Compression/See Misfiring and Running Rough.Exhaust Smoke Can Not Be Seen While Starting
Possible Causes/Corrections
No Fuel in Tank(s)/Check fuel level visually (do not use the
Possible Causes/Corrections
Cold Outside Temperatures/It can be necessary to use starting aids, or to heat engine oil or coolant at temperatures below -12° C (10° F). Air in Fuel System/With air in the fuel system, the engine will normally be difficult to start, run rough and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air can not be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak. Low Quality Fuel/Remove a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, remove fuel from the tank until it is free of water and fill with a good quality fuel. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines.Change the fuel filter and "prime" (remove the air and/or low quality fuel from the fuel system) the fuel system with the fuel priming pump. If there is no water in the fuel, prime and start the engine by using an outside source of fuel. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel. Prime the fuel system if necessary. Low Fuel Pressure/Change the primary and secondary fuel filters and check to make sure the fuel lines are not plugged or damaged. If the filters or lines are not the cause, a repair or replacement of the fuel transfer pump is needed. Fuel Injection Timing Not Correct/Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Valve Adjustment Not Correct/Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in.) and exhaust valve clearance is 0.64 mm (.025 in.). Bad Fuel Nozzle(s)/Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual. Low Compression/See Misfiring and Running Rough.Exhaust Smoke Can Not Be Seen While Starting
Possible Causes/Corrections
No Fuel in Tank(s)/Check fuel level visually (do not use the