101602-0961 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016020961 1156012022

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-0961 1016020961

ISUZU 1156012022 1156012022

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Cross reference number

ZEXEL 101602-0961 1016020961

ISUZU 1156012022 1156012022

Zexel num

Bosch num

Firm num

Name

101602-0961

1156012022 ISUZU

INJECTION-PUMP ASSEMBLY
6BB1 * 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

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 9.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 57.4 56.4 58.4

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.3+-0.5

Pump speed r/min 325 325 325

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)Main spring setting (3)Set idle sub-spring
----------
K=5
----------

Speed control lever angle

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

----------
a=77deg+-5deg b=23deg+-5deg

Stop lever angle

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

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

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(90deg)

Information:

Table 1
Required Tools
Tool Part Number Part Description Qty
A 380-5200 Tool Kit 1
B 366-7782 Attenuator 1 Testing Procedure
Perform a "Manual Diesel Particulate Filter Regeneration" using the electronic service tool. If the "Manual Diesel Particulate Filter Regeneration" procedure follows the removal of excess oil from the exhaust system, proceed to Step 2.
Follow the procedure that is detailed by Step 1.b through to Step 1.m to clean oil from the exhaust system.
Remove excess oil from all pipes with a clean cloth.
Remove the DPF from the bracket for the clean emission module. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Remove" for the correct procedure.
Use a suitable supporting device, position the DPF in a vertical position. Ensure that the inlet side of the DPF faces in a DOWNWARDS position.
Let the DPF drain overnight. The oil will collect inside the inlet face of the DPF. Position a suitable container under the inlet face of the DPF. Incline the inlet face of the DPF to drain the oil into the container.
If amount drained from DPF equals less than 1 L (0.26 US gal), proceed to Step 1.g. If amount is greater than 1 L (0.26 US gal), then the DPF should be replaced.
Remove excess oil from the inlet and outlet of the DPF with a clean cloth.
Install the DPF from the bracket for the clean emission module. Refer to Disassembly and Assembly, "Diesel Particulate Filter - Install" for the correct procedure.
Start the engine. Operate the engine a 100 percent throttle for a MINIMUM of 20 minutes. Do not operate the application under load at this time period.
After 20 minutes, use the electronic service tool to perform the "DPF Desulphation Procedure". The "DPF Desulphation Procedure" will last 60 minutes.
Once the "DPF Desulphation Procedure" has been completed, observe the soot load. If the soot load is at a value less than 80 percent, then the application can be returned to service.
Check the application for any signs of visible black smoke coming from the exhaust stack after the cleaning procedure has been completed. This could indicate a cracked DPF that will need to be replaced.Note: Black soot residue on the surface of the inside of the exhaust stack does not necessarily indicate a cracked DPF therefore should not be used in determining a problem with the DPF.
If white smoke does not dissipate, contact the Technical Communicator at a Caterpillar dealer. For further assistance, the Technical Communicator can confer with the Dealer Solutions Network.
After the manual DPF regeneration is complete, operate the engine at 1800 rpm for a MINIMUM of 20 minutes to stabilize the DPF temperatures.Note: The engine must maintain a steady speed for the entire duration of the test.
Hot engine components can cause injury from burns. Before performing maintenance on the engine, allow the engine and the components to cool.
Illustration 1 g02597531
Typical example (1) DPF Outlet Cap (2) Filter Paper (3) Hose Assembly (4) Air Pump
Illustration