101601-7720 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016017720 1156012501


 

Information injection-pump assembly

ZEXEL 101601-7720 1016017720
ISUZU 1156012501 1156012501
101601-7720 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101601-7720 1016017720
ISUZU 1156012501 1156012501


Zexel num
Bosch num
Firm num
Name
101601-7720 
 
1156012501  ISUZU
INJECTION-PUMP ASSEMBLY
6BF1 * K

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   132424-0620
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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)
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   -
Rack position   13
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   71 69.5 72.5
Max. variation between cylinders %   0 -2.5 2.5
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
Average injection quantity mm3/st.   8.6 7.3 9.9
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(13)
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   71 70 72
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   13.05+-0 .5
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   78.8 77.2 80.4
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   12.95+-0 .5
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   75.2 73.6 76.8
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   12.65+-0 .5
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   53.3 51.7 54.9
Fixing the lever   *
Timer adjustment
Pump speed r/min   1350
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1400
Advance angle deg.   1.3
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   2.3 1.8 2.8
Timer adjustment_04
Pump speed r/min   1600
Advance angle deg.   4 3.5 4.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-7720
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=24 RAL=16.2+0.2mm
----------

Speed control lever angle

Test data 101601-7720
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=20deg+-5deg b=41deg+-3deg

Timing setting

Test data 101601-7720
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:


Oil Filters (1), Crankcase Drain (2), Oil Filler (3), Oil Level Gauge (4), Fuel Filters & Priming Pump (5), Air Cleaner with Service Indicator (6), Aftercooler (7), Turbochargers (8), Crankcase Breather with Element (9), Alternator (10), Electronic Governing/Control Module (11), Primary Fuel Filter (12), Oil Cooler (13), Magnetic Speed Sensor (14), Jacket Water Pump (15), Jacket Water Heater (16), Fumes Disposal Drain (17), Ether Canister Bracket (18), Starting Motor (19) and Cooling System Drain (20).
Main Control (GSC) Panel (21), Emergency Stop Pushbutton (22), Engine Control Switch (23), Alarm Module (24).Engine Description
Caterpillar 3412 Generator Set Engines are 27 liter (1649 cu. in.), 137 mm (5.4 in.) bore and 152.4 mm (6.0 in.) stroke, four cycle, 12 cylinder, 65 degree vee diesel design. The engine is available in twin turbocharged or series turbocharged arrangements with jacket water aftercooling and direct fuel injection.The engine and components are designed for high power output. The reduced size and weight plus increased fuel economy provide maximum performance and lower cost per unit of power. The 3412 Generator Set is offered at 1500 rpm, 50 Hz and 1800 rpm, 60 Hz arrangements with various output power ratings. Contact your Caterpillar dealer for information on these power ratings.Larger diameter plungers and a higher injection rate camshaft are incorporated in the valve train/fuel system. The fuel lines are made of high strength steel and the ends of the lines have collared washers to increase reliability. The cooling system has a gear driven centrifugal water pump, two thermostats (one for each bank) which regulate engine coolant temperature, and an oil cooler.The engine lubricating oil, which is both cooled and filtered, is supplied by a gear driven pump. Bypass valves provide unrestricted flow of lubrication oil to engine parts when oil viscosity is high, or either the oil cooler or oil filter elements should become plugged.The 3412 Generator Set Engine is electronically governed and features an exclusive electronic Engine Control Module (ECM). The ECM is a microprocessor-based system that provides full range isochronous speed governing which can operate in speed droop with a zero to ten percent adjustment range.The ECM also provides a cold mode starting strategy, air to fuel ratio control for transient smoke limiting, automatic turbocharger boost pressure and rack position sensor calibration, engine protection and diagnostics.The 3412 engines are equipped with the Electronic Modular Control Panel (EMCP II). The EMCP II is the next generation of engine/generator controls for more accurate, reliable monitoring of engine operating parameters and generator AC voltage metering.The SR4 generator features single bearing, wye connected, brushless, permanent magnet excited designed to match the output characteristics of the engine. These packaged generator sets are designed, manufactured and tested in accordance with ISO 9001 to ensure the highest possible quality on a worldwide basis.Engine efficiency and engine performance and efficiency of emissions controls depend on adherence to proper operation and maintenance recommendations, and the use of recommended fuels, coolants and lubrication oils. To minimize expenses and provide maximum utilization and performance of your

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