Information injection-pump assembly
ZEXEL
101601-7774
1016017774
ISUZU
1156013124
1156013124
Rating:
Service parts 101601-7774 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-104-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-7774
1016017774
ISUZU
1156013124
1156013124
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
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
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
-
Rack position
12.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
78
76.4
79.6
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
260
260
260
Average injection quantity
mm3/st.
8.1
6.8
9.4
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(12.7)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
78
77
79
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
I
Rack position
15+-0.5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
92
92
100
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1350--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=78
----------
----------
T1=78
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=35mm
----------
a=42deg+-5deg b=(45deg)+-3deg
----------
aa=35mm
----------
a=42deg+-5deg b=(45deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
USE FUEL CONSUMPTION, SERVICE HOURS OR TIME INTERVAL, WHICHEVER OCCURS FIRST.Daily
Walk-Around Inspection - Inspect engine, radiator and generator/control panel for dirt & debris, moisture, foreign objects, loose or broken fittings and wires, guards and components. Repair as necessary Engine Crankcase - Check oil level Cooling System - Check coolant level, Check for proper operation of coolant heater Air Cleaner Indicator - Check Air Starting Motor (If Equipped) - Check level; Drain water SR4 Generator - Check frequency (rpm) and generated voltage for proper settings and stability; record readingsEvery 250 Hours or 25 000 L (6500 gal) of Fuel*
Scheduled Oil Sampling (S O S)** - Obtain Engine Oil and Filters - Replace Fuel System - Drain water & sediment from tank; Replace final filter/Clean primary filter Cooling System - Test for coolant additive concentration; Add liquid coolant additive; Clean radiator fins Crankcase Breathers - Clean Batteries - Clean/Inspect and check electrolyte level Belts, Hoses and Clamps - Inspect/Check Engine Air Cleaners - Clean/Replace SR4 Generator - Check space heater (if equipped) Engine Speed Sensors (Magnetic Pickup) - Inspect/Clean at first oil change Valve Lash** - Check/Adjust at first oil changeEvery 1000 Hours or 100 000 L (26,000 gal) of Fuel*
Engine Protection Controls - Inspect for proper operation SR4 Generator - Check windings and record megohmeter readings (Refer to SEHS9124)Every 3000 Hours or 300 000 L (78,000 gal) of Fuel*
Engine Valve Lash - Check/Adjust, Inspect valve rotators Turbocharger - Inspect for proper operation Engine Mounts and Crankshaft Vibration Damper - Inspect/Check Cooling System - Clean/Flush/Change coolant and replace thermostat SR4 Generator - Lubricate bearings (Refer to SEBU6150) PAR Analysis - ObtainEvery 5000 Hours or 500 000 L (130,000 gal) of Fuel*
Fuel Injection Nozzles - Test/Exchange Starting Motor and Alternator - Inpect for proper operation Turbochargers - Inspect/Rebuild or Exchange Jacket Water Pump - Inspect/Rebuild or Exchange Engine Speed Sensors (Magnetic Pickup) - Inspect/CleanOverhaul Every 10,000 Hours or 1 000 000 L (260,000 gal) of Fuel*
Cylinder Heads, Oil Pump, Fuel Transfer Pump - Inspect/Rebuild or Exchange Piston Rings, Main Bearings, Rod Bearings, Valve Rotators and Crankshaft Seals - Install new Fuel Injection Nozzles and Fuel Injection Pump - Test Connecting Rods, Pistons, Cylinder Liners, Crankshaft, Camshaft, Cam Bearings, Damper, Fuel Pump Camshaft, Cam Followers and Fuel Racks - Inspect/Replace Gear Train Gears & Bushings and Driven Unit Alignment Oil Cooler and Aftercooler Core - Clean/Test Coolant Analysis - Obtain SR4 Generator - Inspect/Clean windings*First Perform Previous Service Hour Items Caterpillar suggests that fuel consumption be used as the preferred method of determining maintenance intervals. Fuel consumption/Hours to Overhaul interval will vary depending on the proper application of your engine rating and maintenance practices.
Walk-Around Inspection - Inspect engine, radiator and generator/control panel for dirt & debris, moisture, foreign objects, loose or broken fittings and wires, guards and components. Repair as necessary Engine Crankcase - Check oil level Cooling System - Check coolant level, Check for proper operation of coolant heater Air Cleaner Indicator - Check Air Starting Motor (If Equipped) - Check level; Drain water SR4 Generator - Check frequency (rpm) and generated voltage for proper settings and stability; record readingsEvery 250 Hours or 25 000 L (6500 gal) of Fuel*
Scheduled Oil Sampling (S O S)** - Obtain Engine Oil and Filters - Replace Fuel System - Drain water & sediment from tank; Replace final filter/Clean primary filter Cooling System - Test for coolant additive concentration; Add liquid coolant additive; Clean radiator fins Crankcase Breathers - Clean Batteries - Clean/Inspect and check electrolyte level Belts, Hoses and Clamps - Inspect/Check Engine Air Cleaners - Clean/Replace SR4 Generator - Check space heater (if equipped) Engine Speed Sensors (Magnetic Pickup) - Inspect/Clean at first oil change Valve Lash** - Check/Adjust at first oil changeEvery 1000 Hours or 100 000 L (26,000 gal) of Fuel*
Engine Protection Controls - Inspect for proper operation SR4 Generator - Check windings and record megohmeter readings (Refer to SEHS9124)Every 3000 Hours or 300 000 L (78,000 gal) of Fuel*
Engine Valve Lash - Check/Adjust, Inspect valve rotators Turbocharger - Inspect for proper operation Engine Mounts and Crankshaft Vibration Damper - Inspect/Check Cooling System - Clean/Flush/Change coolant and replace thermostat SR4 Generator - Lubricate bearings (Refer to SEBU6150) PAR Analysis - ObtainEvery 5000 Hours or 500 000 L (130,000 gal) of Fuel*
Fuel Injection Nozzles - Test/Exchange Starting Motor and Alternator - Inpect for proper operation Turbochargers - Inspect/Rebuild or Exchange Jacket Water Pump - Inspect/Rebuild or Exchange Engine Speed Sensors (Magnetic Pickup) - Inspect/CleanOverhaul Every 10,000 Hours or 1 000 000 L (260,000 gal) of Fuel*
Cylinder Heads, Oil Pump, Fuel Transfer Pump - Inspect/Rebuild or Exchange Piston Rings, Main Bearings, Rod Bearings, Valve Rotators and Crankshaft Seals - Install new Fuel Injection Nozzles and Fuel Injection Pump - Test Connecting Rods, Pistons, Cylinder Liners, Crankshaft, Camshaft, Cam Bearings, Damper, Fuel Pump Camshaft, Cam Followers and Fuel Racks - Inspect/Replace Gear Train Gears & Bushings and Driven Unit Alignment Oil Cooler and Aftercooler Core - Clean/Test Coolant Analysis - Obtain SR4 Generator - Inspect/Clean windings*First Perform Previous Service Hour Items Caterpillar suggests that fuel consumption be used as the preferred method of determining maintenance intervals. Fuel consumption/Hours to Overhaul interval will vary depending on the proper application of your engine rating and maintenance practices.