101602-0850 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016020850 1156011661

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-0850 1016020850

ISUZU 1156011661 1156011661

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Service parts 101602-0850 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2190

3. GOVERNOR 105410-6070

4. SUPPLY PUMP 105220-4561

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-3230

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4372

11. Nozzle and Holder 5-15300-103-2

12. Open Pre:MPa(Kqf/cm2) 14.7{150}

13. NOZZLE-HOLDER 105030-3391

14. NOZZLE

105015-3930

15. NOZZLE SET

Include in #1:

101600-3040 as _

101600-3041

101602-0850 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101602-0850 1016020850

ISUZU 1156011661 1156011661

Zexel num

Bosch num

Firm num

Name

101602-0850

1156011661 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1 * K 14BE PE6A PE

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

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 7.3

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 63.8 62.8 64.8

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.2

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 66.4 64.4 68.4

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 4.5+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Set idle sub-spring (3)Main spring setting
----------
K=12
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=5deg+-5deg b=18deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=12deg+-5deg b=46deg+-5deg

Information:

Illustration 1 g00656709
(1) Error code (2) Activity on CAT Data Link (3) First digit of error code (4) The CCM is transmitting on RS 232C. (5) Second digit of error code (6) The CCM is receiving data on the RS 232C.The values E, 0, and 0 indicate an error code of 00. The code E00 means that no faults are present, and the CCM is in normal operating mode. The complete list of error codes are in the Operation and Maintenance Manual, "Troubleshooting" section. The periods on the display will flash when information is transmitted on the CAT Data Link. The periods on the display will flash when information is transmitted on the RS-232C port. No period indicates that no activity is taking place.Note: Units with the part number 117-6170 Customer Communication Module will display the faults that have been logged. Each fault will be displayed for 2 seconds in 60 second intervals. This flashing fault log will not appear for any other version of CCM. The fault log can be cleared by using the PC software for the CCM.CCM Power Up Display
The CCM display will perform a lamp test (8.8.8.). The parameters for communication protocol (n81 9600 E00) will be displayed next. An example of the power up sequence is given below:
Table 1
8.8.8. n81 9600 E00
8.8.8. All of the segments are turned on for a two second lamp test.
n81
n
8
1 No parity (default value)
Eight data bits (default value)
One stop bit (default value)
9600 Rate of Communication (default value)
E00 Error Code
No faults are present. The values for communication can be changed by using a host device or by using the PC software for the CCM. Refer to "Caterpillar CCM PC For Windows: Getting Started Manual". The values for communication must match the values for the modems (if used) and the values for the host device.