Information injection-pump assembly
ZEXEL
101601-4580
1016014580
ISUZU
5156009541
5156009541
Rating:
Service parts 101601-4580 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-089-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-4580
1016014580
ISUZU
5156009541
5156009541
Zexel num
Bosch num
Firm num
Name
101601-4580
5156009541 ISUZU
INJECTION-PUMP ASSEMBLY
6BD1 * K 14BE PE6A PE
6BD1 * K 14BE PE6A PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
11.1
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
66.8
65.3
68.3
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
325
325
325
Average injection quantity
mm3/st.
9.3
8
10.6
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(11.1+
-0.5)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
66.8
65.8
67.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
11.2+-0.
5
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
74
72.4
75.6
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
11.05+-0
.5
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
71
69.4
72.6
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
10.85+-0
.5
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
48
46.4
49.6
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
E
Rack position
10.95+-0
.5
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
46.2
44.2
48.2
Fixing the lever
*
Injection quantity adjustment_08
Adjusting point
F
Rack position
11.25+-0
.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
50
48
52
Fixing the lever
*
Injection quantity adjustment_09
Adjusting point
I
Rack position
R3(13.6+
-0.5)
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
82
82
87
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.
1.3
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
2.3
1.8
2.8
Timer adjustment_04
Pump speed
r/min
1600
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
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=01 R1=12mm N1=225r/min
----------
----------
T1=01 R1=12mm N1=225r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'b.'
----------
----------
a=19.5deg+-5deg b=39deg+-3deg
----------
----------
a=19.5deg+-5deg b=39deg+-3deg
Information:
1. Remove suction bell (3) and tubes, oil supply tube (2) and BrakeSaver oil supply tube (1) from the engine block and oil pump. 2. Remove three bolts (5) and oil pump (4) from the engine. The following steps are for installation of the oil pump.3. Put oil pump (4) in position on the engine. Make sure the oil pump gear is engaged with the crankshaft gear, and install three bolts (5) that hold the oil pump.4. Put clean engine oil on the O-ring seals on the oil tubes.5. Install suction bell (3) and tubes, oil supply tube (2) and the BrakeSaver oil supply tube (1).END BY:a. install oil pan (BrakeSaver)Disassemble Oil Pump (BrakeSaver)
START BY:a. remove oil pump (BrakeSaver) 1. Remove the bolt and washer that hold drive gear (1) on the shaft.2. Use tooling (A) to remove drive gear (1) from the shaft. Remove the key from the shaft. Put alignment marks on the pump bodies so they can be assembled in the correct position. 3. Remove retainer (3) for the bypass valve. Remove the spring and bypass valve.4. Remove bolts (4) that hold pump body (2) to the main pump body. Remove pump body (2).5. Use tooling (B) to remove the bearings from pump body (2). 6. Remove gears (7). Put identification marks on the gears so they can be assembled in the same position.7. Remove spacer (6) from main oil pump body (5). Use tooling (B) to remove the bearings from spacer (6).8. Remove the gears from main oil pump body (5). 9. Use tooling (B) to remove the bearings from the main oil pump body.Assemble Oil Pump (BrakeSaver)
1. Use tooling (A) to install bearings (2) until they are even with the outside surface of main oil pump body (1). Install bearings (2) so the joints in the bearings are 30° 15° from the center line of the bearing bores and toward the oil pump outlet passage as shown. 2. Use tooling (A) to install bearings (3) in the spacer. Install the bearings until they are in position an equal distance in from each side of the spacer. Install the bearings with the oil holes in the bearings in alignment with the oil holes in the spacer and the joints in the bearings in alignment with the cavity on the spacer as shown. 3. Put clean engine oil on all the gears and bearings before they are assembled in the oil pump. Install idler and drive gears (5) in the main oil pump body.4. Install spacer (4) on the gear shafts with the smaller cavity out and the oil holes in the spacer toward the pump outlet passage as shown. 5. Use tooling (A) to install bearings (6) in pump body (7) until they are 1.52 0.25 mm (.060 .010 in.) from the inside edge of the bearing bores. Install the bearings so the joints in the bearings are 30° 15° from the center line of the bearing bores and toward
START BY:a. remove oil pump (BrakeSaver) 1. Remove the bolt and washer that hold drive gear (1) on the shaft.2. Use tooling (A) to remove drive gear (1) from the shaft. Remove the key from the shaft. Put alignment marks on the pump bodies so they can be assembled in the correct position. 3. Remove retainer (3) for the bypass valve. Remove the spring and bypass valve.4. Remove bolts (4) that hold pump body (2) to the main pump body. Remove pump body (2).5. Use tooling (B) to remove the bearings from pump body (2). 6. Remove gears (7). Put identification marks on the gears so they can be assembled in the same position.7. Remove spacer (6) from main oil pump body (5). Use tooling (B) to remove the bearings from spacer (6).8. Remove the gears from main oil pump body (5). 9. Use tooling (B) to remove the bearings from the main oil pump body.Assemble Oil Pump (BrakeSaver)
1. Use tooling (A) to install bearings (2) until they are even with the outside surface of main oil pump body (1). Install bearings (2) so the joints in the bearings are 30° 15° from the center line of the bearing bores and toward the oil pump outlet passage as shown. 2. Use tooling (A) to install bearings (3) in the spacer. Install the bearings until they are in position an equal distance in from each side of the spacer. Install the bearings with the oil holes in the bearings in alignment with the oil holes in the spacer and the joints in the bearings in alignment with the cavity on the spacer as shown. 3. Put clean engine oil on all the gears and bearings before they are assembled in the oil pump. Install idler and drive gears (5) in the main oil pump body.4. Install spacer (4) on the gear shafts with the smaller cavity out and the oil holes in the spacer toward the pump outlet passage as shown. 5. Use tooling (A) to install bearings (6) in pump body (7) until they are 1.52 0.25 mm (.060 .010 in.) from the inside edge of the bearing bores. Install the bearings so the joints in the bearings are 30° 15° from the center line of the bearing bores and toward
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Isuzu
101601-4580
5156009541
INJECTION-PUMP ASSEMBLY
6BD1
6BD1