101601-7020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016017020 1156008800

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-7020 1016017020

ISUZU 1156008800 1156008800

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Buy INJECTION-PUMP ASSEMBLY 101601-7020 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-7020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-0830

3. GOVERNOR 105931-0630

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS 105644-0010

6. COUPLING PLATE 105661-0640

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4823

11. Nozzle and Holder 1-15300-104-2

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101601-7020 as INJECTION-PUMP ASSEMBLY

106681-4120 as _

Cross reference number

ZEXEL 101601-7020 1016017020

ISUZU 1156008800 1156008800

Zexel num

Bosch num

Firm num

Name

101601-7020

1156008800 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 A

Rack position 13.3

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 76.2 74.7 77.7

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(13.3)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 76.2 75.2 77.2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position 13.35+-0 .5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 84.7 83.1 86.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position 13.25+-0 .5

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 81.2 79.6 82.8

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position 12.95+-0 .5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 58.3 56.7 59.9

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position 16.2+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 93 93 101

Fixing the rack *

Timer adjustment

Pump speed r/min 1350

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1400

Advance angle deg. 1.2

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 2.2 1.7 2.7

Timer adjustment_04

Pump speed r/min 1600

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Torque control stroke: L1 (3)RACK LIMIT (4)Because the figures in brackets are the target values at torque cam adjustment, perform final adjustment in accordance with governor and injection quantity adjustment standards. (5)Perform governor spring adjustment by setting lever a. (6)After adjustment of the lever a setting, set the lever so that idle set point H can be obtained and confirm standard b. (7)After completing final adjustment, set the lever to obtain J. (8)Next, confirm rack position R1 or more is obtained when rotation is stopped. (9)In this condition, move the lever to the full position and confirm standard c. (excess fuel for starting operation limit). (10)After completing final adjustment, set speed at N1 using lever b. (11)In this condition, after operating the lever to the full position, confirm no excess fuel for starting (black smoke prevention limit). (12)For the excess fuel setting for starting rack position point I set the lever to obtain standard c in step (9) and then set the rack limit.
----------
T1=24 L1=1+-0.05mm R1=11.8mm N1=225r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'b.'
----------

----------
a=42deg+-5deg b=41deg+-3deg

Information:

Caterpillar Reference Material
Oil
SEBD0640 Oil and Your EngineSEBU6310 EMA Engine Oil Data BookPEDP7105 Scheduled Oil SamplingPEDP7122 Question & Answer BookletPEHP0002 Cat Molybdenum Grease (MPGM)PEHP0003 Cat Lithium Grease (MPGL)PEHP0017 Cat Special Purpose Grease (SPG)PEHP1020 Cat Diesel Engine Oil (CF-4) Data Sheet (North America)PEHP1026 Cat Diesel Engine Oil (CF-4) Data Sheet (International)PEHP6001 How to Take a Good Oil SamplePEWP9733 Cat Fluids SelectorFuel
SEBD0717 Diesel Fuels and Your EngineSEHS7067 Fuels for Caterpillar Diesel EnginesLEKQ3363 Caterpillar Engine Data Sheet 60.1 (Fuels Recommended For Use In Caterpillar Truck Engines)Coolant
SEBD0518 Know Your Cooling SystemSEBD0970 Coolant and Your EngineService Manuals
SEBR0514 Low Emission SystemSEBR0560 3406C (Mechanical) Service Manual (3ZJ16182 and Up, 5KJ07800 and Up)SENR5505 3406C (Electronic) Service Manual (4CK00846 and Up)Special Instructions
The following Special Instructions pertain to the operation, maintenance, diagnostic tooling and programming of the PEEC system. Some of these publications will be included in the tool kits, the others will be available thru your Caterpillar dealer.SEHS7808 Using the 6V3060 Low Emission System TesterSEHS8622 Using the FT1984 Air-To-Air Aftercooler Leak Test GroupSEHS8627 and SEHS9083 Using the 1U5540 Tool GroupSEHS8741 Using the 8C5919 Service Program ModuleSEHS8742 Using the 8T8697 Electronic Control Analyzer Programmer (ECAP)SEHS8743 Using the 8C4629 Digital Diagnostic Tool (DDT) with Programmable Electronic Engine Control ModuleSEHS8746 Using the 1U5540 Tool GroupSEHS8807 Programmable Electronic Engine Control Screen Map(s)SEHS9031 Storage Procedure for Caterpillar ProductsSEHS9349 Using the 8C5919 Service Program ModuleMiscellaneous
LEBT8121 Truck Engine Application and Installation Guide (4-88)LEDT4211 PAR DirectoryLEDT5092 Driving Techniques For Maximum Fuel EconomyLEGT5087 Truck Engine Application and Installation GuideLEHQ6101 General Instructions and Application GuideLEKT8467 Specing for Peak PerformanceLEXT7056 Performance Analysis Report (PAR) Testing for 3406 Electronic Truck EnginesPEDP0026 Power Analysis ReportSEBD0794 3400 Engine-Major Component Performance GuideSEBF8029 Index to Guidelines for Reusable Parts and Salvage OperationsSEBF8062 Guideline for Reusable Parts (Cleaning and Inspection of Air Filters)SELF5052 Emission Related Components WarrantyAdditional Reference Material
ASTM D217-68 - Worked PenetrationASTM D2896 - TBN MeasurementsASTM D2982BASTM D3828AASTM D445ASTM D893ASTM 4985-89 - GM-6038M SpecificationASTM Specs can normally be obtained from your local technological society, library or college.SAE J313 - Diesel FuelsSAE J754 - NomenclatureSAE J183 - ClassificationSAE Specs can be found in your SAE handbook or can be obtained from your local library, college or technological society.* SAE handbooks can be obtained directly from:SAE International
400 Commonwealth Drive
Warrendale, PA USA 15096-0001
All of the above publications are available through your Caterpillar dealer.Customer Specified Reference Numbers
Below is space for information on the programmed specifications to be filled in by the owner. ENGINE: 3406 Electronic* VEHICLE IDENTIFICATION NO. (VIN)____________________* RATING SELECTION NUMBER____________________* CUSTOMER PASSWORDS: Password No. 1 ____________________Password No. 2 ____________________* VEHICLE SPEED PARAMETERS: Vehicle Speed Calibration____________________ppmTachometer Calibration____________________pprVehicle Speed Limit (VSL)____________________mph (km/h)5 mph Vehicle Speed Droop ____________________Engine RPM @ VSL____________________rpm* CRUISE CONTROL (CC) PARAMETERS: Low Cruise Control Speed Set Limit (LCC)____________________mph (km/h)High Cruise Control Speed Set Limit (HCC)____________________mph (km/h)Engine Retarder Mode ____________________Cruise Switch Configuration ____________________* PTO GOVERNOR PARAMETERS: PTO Mode Speed Limit____________________mph (km/h)PTO Mode Engine Speed (rpm) Limit____________________rpmPTO Engine Speed Ramp Rate____________________rpm/sec.* PROGRESSIVE SHIFTING PARAMETERS: Low Gears #1 (LoGr#1) Engine RPM Limit____________________rpmLow Gears #1 (LoGr#1)