Information injection-pump assembly
ZEXEL
101601-4940
1016014940
ISUZU
1156008153
1156008153
Rating:
Service parts 101601-4940 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
101601-4940
1016014940
ISUZU
1156008153
1156008153
Zexel num
Bosch num
Firm num
Name
101601-4940
1156008153 ISUZU
INJECTION-PUMP ASSEMBLY
6BD1T * K
6BD1T * K
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
3.4
3.35
3.45
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
-
Rack position
10.7
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
72
71
73
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
9.6+-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
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
10.7+-0.
5
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
72
71
73
Basic
*
Fixing the lever
*
Boost pressure
kPa
8
8
Boost pressure
mmHg
60
60
Injection quantity adjustment_04
Adjusting point
B
Rack position
10.85+-0
.5
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
81.9
80.3
83.5
Fixing the lever
*
Boost pressure
kPa
8
8
Boost pressure
mmHg
60
60
Injection quantity adjustment_05
Adjusting point
C
Rack position
10.6+-0.
5
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
57.8
56.2
59.4
Fixing the lever
*
Boost pressure
kPa
8
8
8
Boost pressure
mmHg
60
60
60
Injection quantity adjustment_06
Adjusting point
I
Rack position
12.8+-0.
5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
80
80
85
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
10.3
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
10.5
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
10.6
Remarks
Measure actual boost pressure.
Measure actual boost pressure.
Timer adjustment
Pump speed
r/min
1250
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
1
0.1
1
Timer adjustment_03
Pump speed
r/min
1350
Advance angle
deg.
1
0.5
1.5
Timer adjustment_04
Pump speed
r/min
1450
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT: RAL
(3)Boost pressure: not less than BP1
(4)Boost pressure: not less than BP2
(5)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.
(6)Perform governor spring adjustment by setting lever a.
(7)After adjustment of the lever a setting, set the lever so that idle set point H can be obtained and confirm standard b.
(8)After completing final adjustment, set the lever to obtain J.
(9)Next, confirm rack position R1 or more is obtained when rotation is stopped.
(10)In this condition, move the lever to the full position and confirm standard c. (excess fuel for starting operation limit).
(11)After completing final adjustment, set speed at N1 using lever b.
(12)In this condition, after operating the lever to the full position, confirm no excess fuel for starting (black smoke prevention limit).
(13)For the excess fuel setting for starting rack position point I, set the lever to obtain standard c in step (10) and then set the rack limit.
----------
T1=46 RAL=(13)mm BP1=8kPa(60mmHg) BP2=0kPa(0mmHg) R1=11.8mm N1=225r/min
----------
----------
T1=46 RAL=(13)mm BP1=8kPa(60mmHg) BP2=0kPa(0mmHg) R1=11.8mm N1=225r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'b.'
----------
----------
a=40deg+-5deg b=34deg+-3deg
----------
----------
a=40deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
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=12deg
----------
a=(20deg)
----------
aa=12deg
----------
a=(20deg)
Information:
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Turn the crankshaft until the "C" mark on the crankshaft gear is in alignment with the "C" mark on the camshaft gear. To keep the engine timing correct during removal and installation of the camshaft, put a mark on the teeth of the fuel injection pump drive gear and idler gear at location (A). Put a mark on the teeth of the idler gear and camshaft gear at location (B). When installing the camshaft, the engine timing will be correct when the marks at locations (A) and (B) are in alignment and the "C" marks on the crankshaft and camshaft gears are in alignment.2. Remove the bolts, lock and washer (1) that hold the camshaft in position.
Do not cause damage to the lobes or bearings when the camshaft is removed.
3. Remove the camshaft and gear (2).4. If necessary, remove the bolts and gear. The following steps are for the installation of the camshaft.5. Put the camshaft drive gear in position on the end of the camshaft, and install the bolts that hold it. Tighten the bolts to a torque of 55 7 N m (41 5 lb ft).
Do not cause damage to the lobes or bearings when the camshaft is installed.
6. Put 2P2506 Thread Lubricant on the camshaft lobes only, and clean engine oil on the bearing journals. Install camshaft (3) aligning the "C" marks and the marks put on the gears during removal.7. Install washer (1), the lock and bolts.End By:a. install valve liftersb. install timing gear cover
Perform Scheduled Oil Sampling on oil wetted compartments after performing service work to check for contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.
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Group cross 101601-4940 ZEXEL
Isuzu
101601-4940
1156008153
INJECTION-PUMP ASSEMBLY
6BD1T
6BD1T