101601-7883 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016017883 1156012684

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101601-7883 1016017883

ISUZU 1156012684 1156012684

Service parts 101601-7883 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2120

3. GOVERNOR

4. SUPPLY PUMP 105220-4781

5. AUTOM. ADVANCE MECHANIS 105612-3200

6. COUPLING PLATE 105661-0431

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5053

11. Nozzle and Holder 1-15300-105-2

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4190

15. NOZZLE SET

Include in #1:

101601-7883 as INJECTION-PUMP ASSEMBLY

106684-4261 as _

106684-4262

106684-4264

Cross reference number

ZEXEL 101601-7883 1016017883

ISUZU 1156012684 1156012684

Zexel num

Bosch num

Firm num

Name

101601-7883
101601-7885

1156012684 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1-T *

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 3.4 3.35 3.45

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 10.9

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 77.4 76.4 78.4

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 9.7+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.9)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 77.4 76.4 78.4

Basic *

Fixing the lever *

Boost pressure kPa 16.7 16.7

Boost pressure mmHg 125 125

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.3

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 80.8 77.6 84

Fixing the lever *

Boost pressure kPa 16.7 16.7

Boost pressure mmHg 125 125

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 53.7 50.5 56.9

Fixing the lever *

Boost pressure kPa 16.7 16.7

Boost pressure mmHg 125 125

Injection quantity adjustment_06

Adjusting point I

Rack position 13+-0.5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 82 82 87

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position (R1-0.4) -0.5

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position (R1-0.4) -0.3

Boost pressure kPa 4.7 4.7 7.4

Boost pressure mmHg 35 35 55

Boost compensator adjustment_03

Pump speed r/min 500 500 500

Rack position R1-0.4

Remarks
Measure actual boost pressure.

Timer adjustment

Pump speed r/min 1300--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1250

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1350

Advance angle deg. 0.7 0.2 1.2

Timer adjustment_04

Pump speed r/min 1450

Advance angle deg. 1.5 1 2

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=A44 BCL=0.5+-0.05mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=40deg+-5deg b=34deg+-3deg

Stop lever angle

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

----------
a=25deg+-5deg b=40deg+-5deg

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)-
----------
aa=13deg
----------
a=(60deg)