101601-4560 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016014560 5156009690

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-4560 1016014560

ISUZU 5156009690 5156009690

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Buy INJECTION-PUMP ASSEMBLY 101601-4560 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-4560 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-0830

3. GOVERNOR 105931-0350

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:

101601-4560 as INJECTION-PUMP ASSEMBLY

106672-9983 as _

Cross reference number

ZEXEL 101601-4560 1016014560

ISUZU 5156009690 5156009690

Zexel num

Bosch num

Firm num

Name

101601-4560

5156009690 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

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 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 R2(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 93 101

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.
----------
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 'b.'
----------

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

Information:

Remove BrakeSaver Control Valve
Do not disconnect any air lines until the air pressure is zero.
1. Loosen the bleed valves and release the air pressure in the air tanks.2. Drain the oil from the oil pan. 3. Remove two short bolts (1) and two longer bolts (3) from manifold (2) and the BrakeSaver housing. Remove manifold (2). Remove the O-ring seals from the manifold. 4. Remove oil temperature sensing unit (4) from the BrakeSaver control valve.5. Disconnect air line (5) and hose assembly (6) from the BrakeSaver control valve. 6. Remove bolt (7) and retainer (8) that hold the oil lines in the BrakeSaver control valve. 7. Disconnect oil lines (9) and (10) from the oil cooler. Remove oil lines (9) and (10) from the BrakeSaver control valve. 8. Remove bolts (12) and BrakeSaver control valve (11) from under the oil pan. The weight is 22 kg (48 lb.).9. Remove elbow (13) from the BrakeSaver control valve. Remove the O-ring seals.Install BrakeSaver Control Valve
1. Inspect the O-ring seals for damage, and make replacements if needed. Put clean engine oil on the O-ring seals. 2. Install the O-ring seals and elbow (3) on the BrakeSaver control valve.3. Make sure the O-ring seals are in position on the face of the BrakeSaver control valve. Put BrakeSaver control valve (1) in position under the oil pan. Install bolts (2) that hold the BrakeSaver control valve to the oil pan. 4. Install oil temperature sensing unit (4) in the BrakeSaver control valve.5. Connect air line (5) and hose assembly (6) to the BrakeSaver control valve. 6. Install O-ring seals (7) and (8) on manifold (9). Install manifold (9) in the BrakeSaver control valve. Install the four bolts that hold the manifold to the BrakeSaver housing. 7. Make sure the O-ring seals are in place on the oil lines, and install oil lines (10) and (11). 8. Install retainer (12) 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 Pipe 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 oil to the correct level. See the Maintenance Guide.Disassemble BrakeSaver Control Valve
START BY:a. remove BrakeSaver control valve 1. Remove O-ring seals (1) from the valve body.
Spring force is behind the cover at removal.
2. Remove four bolts (2) slowly and evenly from cover (4). Remove the cover.3. Remove cover (3) and the seal from the opposite end of the valve body. 4. Remove spool (8) as an assembly.5. Remove spring (7), stop (10), spring (6) and slug (9).6. Remove the O-ring seals and sleeve (5). 7. Remove bolt (11), plate (13) and diaphragm (12) from the spool. Inspect the pin on the spool, and make a replacement of the