101603-0070 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030070 1156015002

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-0070 1016030070

ISUZU 1156015002 1156015002

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Service parts 101603-0070 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-0570

3. GOVERNOR 105931-3160

4. SUPPLY PUMP 105220-4781

5. AUTOM. ADVANCE MECHANIS 105612-3070

6. COUPLING PLATE 105661-0661

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4582

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3952

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101603-0070 as INJECTION-PUMP ASSEMBLY

101606-0002 as _

Cross reference number

ZEXEL 101603-0070 1016030070

ISUZU 1156015002 1156015002

Zexel num

Bosch num

Firm num

Name

101603-0070

1156015002 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

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 -

Rack position 10.8

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 61.4 59.8 63

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. 7.4 6.1 8.7

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(10.8)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 61.4 60.4 62.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 71 69.4 72.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.05

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 66 64.4 67.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 45.7 44.1 47.3

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position 13.6+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 87 87 95

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1400--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1350

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 1.3

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 2.3 1.8 2.8

Timer adjustment_05

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)RACK LIMIT (3)Torque control stroke: L2 (4)Perform speed droop adjustment using the torque control spring in accordance with specification 'a' and confirm specification 'b.' Set the final full speed position lever in accordance with specification 'a.'
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T1=27 L2=(1.1)+-0.05mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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----------
a=42deg+-5deg b=37deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
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a=25deg+-5deg b=40deg+-5deg

0000001501 VARIABLE TORQUE CONTROL

N:Pump speed (r/min) R:Rack position (mm) Adjusting shim A Guide screw B (c) Nut (d) Nut (e) nut Torque control spring adjustment method for model responding to speed droop [Advice] Confirm that adjusting shim (A) thickness t = 1.3~1.5 mm is assembled before beginning adjustment. (1)Temporary idle lever position setting 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (2)Idling spring adjustment 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (3)Governor spring setting adjustment 1. Temporarily fix so that the governor shaft's guide screw B protrudes L2 (18 mm) from the end of the governor. 2. Set the control lever where it contacts the idle stopper bolt. 3. Increase the speed to Nh2+100 r/min or more. 4. Adjust using the two nuts C and D so that L1 = 0.3+0.5 mm and fix temporarily. 5. Adjust the protrusion L2 of the guide screw (B) so that the rack position at Nh1 is Rh1 and at Nh2 is Rh2. Then fix using the nut (E). 6. Further increase the speed and readjust the two nuts (C) and (D) so that there is no change in L1 until Nf+50 r/min. Then fix temporarily. [Advice] When L1 becomes smaller while speed is increasing to Nf+50 r/min, decrease speed by Nh2+100 r/min. Adjust so that L1 is even smaller, then again increase speed to Nf+50 r/min and confirm that L1 does not change. (4)Full load position setting 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (5)Torque control spring adjustment 1. Set the control lever so that it contacts the full speed stopper bolt. 2. At the specified speed Nf, adjust using the full speed stopper bolt so that governing begins, then fix temporarily. 3. Increase the speed and adjust using the two nuts (C) and (D) so that the rack position Rg can be obtained at the specified speed Ng. Fix temporarily. 4. Decrease the speed and confirm the governing point (the beginning of governing point) at the specified speed Nf. 5. Set the speed at Nf-50 r/min. 6. Measure the torque control stroke (L1) and adjust to the specified stroke (L1) using the shim (A). 7. After completing shim adjustment, repeat the above adjustment using the two nuts. 8. After confirming the specifications Nf and Ng, fix the two nuts (C) and (D). 9. In this condition, increase the speed and confirm that R = 0 can be obtained. (6)Full speed lever position setting 1. Set the control lever so that it contacts the full speed stopper bolt. 2. At the specified speed Nu, adjust using the full speed stopper bolt so that governing begins, then fix temporarily 3. Increase the speed and confirm that the specified rack position Ru can be obtained. 4. Adjust using the full speed stopper bolt so that governing begins at the specified speed Nf, then fix. 5. Confirm that the result is the same as that in '(5) Torque control spring adjustment.' 6. Confirm that the control lever operating angle is within the specifications. (7)Rack limit adjustment 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
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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)-
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aa=14deg
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a=(60deg)

Information:

Above 16°C (60°F)
Consult the "Operation" (Operator's) Guide for before starting checks. 1. Turn on the scraper disconnect switch. 2. Move the scraper governor to just past ENGINE STOPPED detent. 3. Push in and turn the start switch to START. Release the switch when the engine starts.
After every 30 seconds of cranking, allow 2 minutes for the starting motor to cool.
4. If the engine oil pressure gauge doesn't register within 10 seconds, push the governor control to the ENGINE STOPPED position to stop the engine. Have corrections made.5. Keep the engine at low idle until the systems are warm.6. Watch all gauges and indicators for correct readings before moving the machine.16°C (60°F) to -12°C (10°F)
1. Follow the steps under "Above 16°C (60°F)."
If the engine does not start after two attempts, use starting fluid. This will prevent excessive battery drain and starting motor overheating.
2. Use starting fluid by pushing the button under the start switch, at 2 second intervals, while cranking the engine. See "Ether Aids" under "Cold Weather Starting Aids."-12°C (10°F) to -26°C (-15°F)
1. Follow the steps under "Above 16°C (60°F)."2. Coolant heaters are required.3. An external battery source may be required if the battery charge is not maintained. See "Boost Starting" under "Cold Weather Starting Aids."4. Starting fluid is required. See "Ether Aids" under "Cold Weather Starting Aids."Below -26°C (-15°F)
1. Follow the steps under "Above 16°C (60°F)."2. Coolant heaters are required.3. An external battery source may be required. See "Boost Starting" under "Cold Weather Starting Aids."4. Starting fluid is required. See "Ether Aids" under "Cold Weather Starting Aids."5. Special lubricants are required. Consult your Caterpillar dealer or refer to Caterpillar Form Number SEBU5338, "Operation, Lubrication and Maintenance Guide for Cold Weather Operation."Starting Aids
Winter Oils
The use of SAE10W viscosity oil in the compartments listed on the chart below will aid in cold weather starting.
Use SAE10W oil only in the temperature ranges indicated.
At lower than above temperatures consult your Caterpillar dealer or refer to the "Operation, Lubrication and Maintenance Guide for Cold Weather Operation," Caterpillar Form Number SEBU5338, for the correct lubricants to use.Ether Aids
Ether is a poison and is flammable.Use it only in well ventilated areas.Use it with care to avoid fires.Avoid breathing the ether vapors, or repeated contact of ether with skin.Do not use ether in environments above 90°C (200°F).
Ether is to be used for cold starting purposes only. Use ether only while cranking the engine. Use it sparingly. Excessive ether can cause piston and ring damage.
Push the button only while cranking the engine.A metered amount of starting fluid (ether) is released each time the button is pushed.After pushing the button, allow 2 seconds before pushing it again.Continue the use of starting fluid every 2 seconds after the engine starts, until it is running smoothly.Batteries
Keep batteries charged to a corrected specific gravity of 1.250 or above. Otherwise, an external electrical source may be required.Boost Starting
Do not allow cable ends to contact each other or the machine.Prevent sparks near the batteries. They could cause battery vapors (hydrogen) to explode.
When