Information injection-pump assembly
ZEXEL
101601-7883
1016017883
ISUZU
1156012684
1156012684
Rating:
Service parts 101601-7883 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-105-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-7883
1016017883
ISUZU
1156012684
1156012684
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
3.4
3.35
3.45
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
10.9
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
77.4
76.4
78.4
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
9.7+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
9.4
8.1
10.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.9)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
77.4
76.4
78.4
Basic
*
Fixing the lever
*
Boost pressure
kPa
16.7
16.7
Boost pressure
mmHg
125
125
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.3
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
80.8
77.6
84
Fixing the lever
*
Boost pressure
kPa
16.7
16.7
Boost pressure
mmHg
125
125
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
53.7
50.5
56.9
Fixing the lever
*
Boost pressure
kPa
16.7
16.7
Boost pressure
mmHg
125
125
Injection quantity adjustment_06
Adjusting point
I
Rack position
13+-0.5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
82
82
87
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
(R1-0.4)
-0.5
Boost pressure
kPa
2
2
4.7
Boost pressure
mmHg
15
15
35
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
(R1-0.4)
-0.3
Boost pressure
kPa
4.7
4.7
7.4
Boost pressure
mmHg
35
35
55
Boost compensator adjustment_03
Pump speed
r/min
500
500
500
Rack position
R1-0.4
Remarks
Measure actual boost pressure.
Measure actual boost pressure.
Timer adjustment
Pump speed
r/min
1300--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1250
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1350
Advance angle
deg.
0.7
0.2
1.2
Timer adjustment_04
Pump speed
r/min
1450
Advance angle
deg.
1.5
1
2
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=A44 BCL=0.5+-0.05mm
----------
----------
T1=A44 BCL=0.5+-0.05mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=40deg+-5deg b=34deg+-3deg
----------
aa=35mm
----------
a=40deg+-5deg b=34deg+-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)B.T.D.C.: aa
(4)-
----------
aa=13deg
----------
a=(60deg)
----------
aa=13deg
----------
a=(60deg)
Information:
Failure to follow these oil recommendations can cause shortened engine life due to deposits and or excessive wear.
Total Base Number (TBN) and Fuel Sulfur Levels For Caterpillar Prechamber Combustion (PC) Diesel Engines
New engine oil must have a TBN of 20 times (for Precombustion Chamber engines) and ten times (for direct injection engines) the percent fuel sulfur as measured by ASTM D2896 method. Refer to the following chart.
Y=oil TBN shown by ASTM D2896. X=percent of fuel sulfur by weight. New oil TBN (1). Change oil when the used oil TBN limit (2) is reached.Caterpillar's 20 times rule for TBN (Reference: Oil and Your Engine, SEBD0640) versus fuel sulfur was a general requirement developed in the early 1980's for Cat prechamber combustion (PC) system engines. Caterpillar still maintains 20 times TBN value for PC engines when using API CE or CF-4 oil (related to fuel sulfur above 0.5 percent). Engines built prior to 1990 can continue to use single grade viscosity oil or commercial oils, provided the engine operates to user satisfaction.Fuel sulfur neutralization of new oil formulations in direct injection (DI) system engines are more effective. Field results indicate that direct injection combustion (DI) systems and the oils now recommended for those engines will operate at an oil TBN equal to ten times the fuel sulfur.Total Base Number (TBN) and Fuel Sulfur Levels For Caterpillar Direct Injection (DI) Diesel Engines
The TBN for a new oil is dependent on the sulfur level of the fuel used. For direct injection engines running distillate diesel fuel, the minimum new oil TBN (by ASTM D 2896) must be 10 times the fuel sulfur level, and the minimum TBN is 5 regardless of sulfur level, see the chart below.TBN vs Fuel Sulfur for Caterpillar DI Diesel Engines
Y=oil TBN shown by ASTM D2896. X=percent of fuel sulfur by weight. New oil TBN (1). Change oil when the used oil TBN limit (2) is reached.In areas where the fuel sulfur exceeds 1.5 percent, choose an oil with the highest TBN that is within the API CF-4 or CG-4 categories, and shorten the oil change period based on oil analysis. The oil analysis should evaluate oil condition and wear metals. High TBN oils that are not within the API CF-4 or CG-4 categories can produce excessive piston deposits leading to a loss of oil control and bore polishing.
Operation at fuel sulfur levels over 1.5 percent may require shortened oil change periods to maintain adequate wear protection.
Lubricant Viscosity Recommendations
The proper SAE viscosity grade oil is determined by the minimum outside temperature at cold engine start up, and the maximum outside temperature during engine operation. Use the minimum temperature column on the chart to determine the oil viscosity required for starting a "cold soaked" engine. Use the maximum temperature column on the chart to select the viscosity for operation at the highest temperature anticipated. In general, use the highest viscosity oil available that still meets the start up temperature requirements. Synthetic Base Stock Oils
Synthetic base stock oils are acceptable