101601-4550 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016014550 5156009680

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-4550 1016014550

ISUZU 5156009680 5156009680

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Buy INJECTION-PUMP ASSEMBLY 101601-4550 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-4550 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-0830

3. GOVERNOR 105931-0340

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS 105644-0010

6. COUPLING PLATE 105661-0640

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4823

11. Nozzle and Holder 1-15300-104-2

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

13. NOZZLE-HOLDER 105030-3201

14. NOZZLE

105015-4130

15. NOZZLE SET

Include in #1:

101601-4550 as INJECTION-PUMP ASSEMBLY

106672-9982 as _

Cross reference number

ZEXEL 101601-4550 1016014550

ISUZU 5156009680 5156009680

Zexel num

Bosch num

Firm num

Name

101601-4550

5156009680 ISUZU

INJECTION-PUMP ASSEMBLY
6BF1 * 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 13.3

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 76.2 74.7 77.7

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. 8.6 7.3 9.9

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(13.3)

Pump speed r/min 950 950 950

Average injection quantity mm3/st. 76.2 75.2 77.2

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position 13.35+-0 .5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 84.7 83.1 86.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position 13.25+-0 .5

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 81.2 79.6 82.8

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position 12.95+-0 .5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 58.3 56.7 59.9

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position 16.2+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 93 93 109

Fixing the rack *

Timer adjustment

Pump speed r/min 1350

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1400

Advance angle deg. 1.2

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 2.2 1.7 2.7

Timer adjustment_04

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)Because the figures in brackets are the target values at torque cam adjustment, perform final adjustment in accordance with governor and injection quantity adjustment standards. (4)Perform governor spring adjustment by setting lever a. (5)After adjustment of the lever a setting, set the lever so that idle set point H can be obtained and confirm standard b. (6)After completing final adjustment, set the lever to obtain J. (7)Next, confirm rack position R1 or more is obtained when rotation is stopped. (8)In this condition, move the lever to the full position and confirm standard c. (excess fuel for starting operation limit). (9)After completing final adjustment, set speed at N1 using lever b. (10)In this condition, after operating the lever to the full position, confirm no excess fuel for starting (black smoke prevention limit). (11)For the excess fuel setting for starting rack position point I set the lever to obtain standard c in step (8) and then set the rack limit.
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T1=24 R1=11.8mm N1=225r/min
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'a.'
----------

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a=42deg+-5deg b=41deg+-3deg

Information:

1. Drain the coolant and oil from the engine.2. Remove bolt (1) and retainer (2) that hold the oil lines in the BrakeSaver control valve. 3. Disconnect oil lines (3) and (4) from the oil cooler. Remove oil lines (3) and (4) from the BrakeSaver control valve.4. Fasten a hoist to the oil cooler. 5. Remove two bolts (8) to disconnect elbow (10) from front bonnet (9). Remove two bolts (7) to disconnect front bonnet (9) from the water pump.6. Remove four bolts (5) to disconnect the rear bonnet from the cylinder block. Disconnect bracket (12).7. Remove oil cooler (11), front bonnet (9) and rear bonnet (6) from the engine as a unit. The weight is approximately 54 kg (120 lb.).8. Make a separation of front bonnet (9) and rear bonnet (6) from oil cooler (11). 9. Clean oil cooler core tubes (13) with a 3.81 mm (.150 in.) diameter rod.Install Oil Cooler (BrakeSaver)
1. Inspect all O-ring seals and gaskets for damage, and make replacements if needed. Put clean engine oil on the O-ring seals. 2. Install rear bonnet (1) and front bonnet (3) on oil cooler (2).3. Fasten a hoist, and put the oil cooler and bonnets as a unit in place on the engine. Connect bracket (4), but do not tighten the bolts at this time.4. Install the gasket and four bolts (4) that hold rear bonnet (1) to the engine block. Do not tighten the bolts at this time.5. Install the gasket and two bolts (5) that hold front bonnet (3) to the water pump. Do not tighten the bolts at this time.6. Install the gasket and bolts (6) that hold elbow (7) to the front bonnet. Tighten all the bolts. 7. Make sure the O-ring seals are in place on the oil lines, and install oil lines (8) and (9). 8. Install retainer (10) to hold the oil lines in the BrakeSaver control valve. If the bottom plug in the oil pan was removed, put the split (seam) of the gasket for the plug against the oil pan. If either plug on the side of the oil pan was removed, put 5P3413 Thread Sealant With Teflon on the threads, and tighten the plug to a torque of 80 11 N m (60 8 lb.ft.).9. Fill the engine with coolant and oil. See the Maintenance Guide.