101901-0660 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1019010660 1156006920

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101901-0660 1019010660

ISUZU 1156006920 1156006920

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Cross reference number

ZEXEL 101901-0660 1019010660

ISUZU 1156006920 1156006920

Zexel num

Bosch num

Firm num

Name

101901-0660

1156006920 ISUZU

INJECTION-PUMP ASSEMBLY
10PB1 * 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 134424-0020

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
R: right hand row, L: left hand row 1L-8R-7L -6R-5L-4 R-3L-10R

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Opposite to the driving side NO.1

Difference between angles 1
Cal 1-8 deg. 27 26.5 27.5

Difference between angles 2
Cal 1-7 deg. 72 71.5 72.5

Difference between angles 3
Cal 1-6 deg. 99 98.5 99.5

Difference between angles 4
Cal 1-5 deg. 144 143.5 144.5

Difference between angles 5
Cal 1-4 deg. 171 170.5 171.5

Difference between angles 6
Cal 1-3 deg. 216 215.5 216.5

Difference between angles 7
Cal 1-10 deg. 243 242.5 243.5

Difference between angles 8
Cal 1-9 deg. 288 287.5 288.5

Difference between angles 9
Cyl.1-2 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 11.7

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 90 88 92

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.7

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 90.4 88.4 92.4

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 11.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 84 83 85

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -13 13

Fixing the rack *

Injection quantity adjustment_05

Adjusting point E

Rack position 15+-0.5

Pump speed r/min 150 150 150

Each cylinder's injection qty mm3/st. 95 95

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1050+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 1.4 0.9 1.9

Timer adjustment_03

Pump speed r/min 1250

Advance angle deg. 3 2.5 3.5

Timer adjustment_04

Pump speed r/min 1350

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Rack limit (operating at delivery) (3)Excess fuel setting for starting: SXL
----------
DL=6-0.5mm SXL=12.4+0.2mm
----------

Speed control lever angle

F:Full speed M:Minimum-maximum speed (1)Fix at full speed at delivery. (2)Set the speed at aa. Set using two nuts.
----------
aa=500r/min
----------
a=8deg+-5deg b=7deg+-5deg

0000000901

F:Full load I:Idle S:Stop (1)Rack position aa (pump speed bb r/min )
----------
aa=7.5mm bb=0r/min
----------
a=32deg+-3deg b=13deg+-5deg c=1.5deg+-5deg

Information:

Table 1
Revision Summary of Changes
01 Added prefix S/N:8811-8299 Description Of Change: The new Diesel Exhaust Fluid (DEF) control unit software now used, has been released to improve the priming performance of DEF pumps in cold environments.Adaptable To:
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.The new and former part numbers are listed in Table 2.
Table 2
Required Parts
Qty Dosing Control Unit (DCU) Dosing Control Unit (DCU) Voltage New Part Number Part Name Former Part Numbers(1)
1 Restriction on Hazardous Substance (RoHS) (DCU) 24V 593-7031 Engine Software 567-5763
1 Restriction on Hazardous Substance (RoHS) (DCU) 12V 593-7030 Engine Software 567-5761
1 Non-Restriction on Hazardous Substance (RoHS) (DCU) 24V 593-7033 Engine Software 539-3577
1 Non-Restriction on Hazardous Substance (RoHS) (DCU) 12V 593-7032 Engine Software 539-3576
(1) The former part number listed is for reference only and may differ.The new software is available in the form of a flash file through the Caterpillar Service Information System (SIS). A newer part number may be available. SIS web only displays the latest available flash file.