Information injection-pump assembly
ZEXEL
101601-7730
1016017730
ISUZU
1156012930
1156012930

Rating:
Cross reference number
ZEXEL
101601-7730
1016017730
ISUZU
1156012930
1156012930
Zexel num
Bosch num
Firm num
Name
101601-7730
1156012930 ISUZU
INJECTION-PUMP ASSEMBLY
6BD1 * K
6BD1 * 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
3.6
3.55
3.65
Rack position
Point A R=A
Point A R=A
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
11.2
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
59.2
57.6
60.8
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
300
300
300
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.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.2)
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
59.2
57.6
60.8
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
10.8+-0.
5
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
67.5
66.5
68.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
10.9+-0.
5
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
64.7
63.1
66.3
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
11.3+-0.
5
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
49.2
47.6
50.8
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
R2(15.7)
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
96
96
101
Fixing the rack
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1050+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1600
Advance angle
deg.
3
2.5
3.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=25
----------
----------
T1=25
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=20deg+-5deg b=40deg+-3deg
----------
----------
a=20deg+-5deg b=40deg+-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 the No. 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=10deg
----------
a=(60deg)
----------
aa=10deg
----------
a=(60deg)
Information:
Engine and Attachment Lifting
When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. Eyebolts and brackets should never be bent and should only be loaded in tension.
Use a hoist to remove heavy components. Lift the engine by using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other, and as near perpendicular as possible to the top of the object being lifted.To remove the engine ONLY, use the lifting eyes equipped with the engine. Lifting eyes are designed for the arrangement as sold and the end user is responsible for providing lifting devices. Alterations to lifting eyes and/or arrangement weight make the lifting eyes and devices obsolete. If you make alterations to the engine package as sold, you are responsible for providing adequate lifting devices.Engine Lifting With Generator (Package)
To remove the engine and generator together, refer to the lifting films located on the engine and generator package. See your Caterpillar dealer for information regarding fixtures and lifting devices for proper lifting of your engine package.Engine Storage
These instructions and recommendations will safeguard the possibility of engine damage if the engines are in storage for one year or less.If the engine will not be or has not been started for several weeks, the lubricating oil will drain from the cylinder walls and piston rings.If an engine remains out of service and its use is not immediately planned, special precautions should be taken. Rust can form on the cylinder liner surface, which will increase engine wear and may result in shorter engine life.To prevent this problem from becoming excessive, be sure all lubrication recommendations mentioned in the Maintenance Schedule are completed.After one year, a complete protection procedure must be followed if the engine is kept in storage longer.If it will be impossible to start the engine periodically, consult your Caterpillar dealer for instructions to prepare your engine for longer storage periods.If an engine remains out of service and its use is not immediately planned, special precautions should be taken. Refer to Storage Procedures For Caterpillar Products, SEHS9031 for more detailed information on engine storage.To prevent excessive engine wear:Be sure all lubrication recommendations mentioned in the Maintenance Schedule intervals chart are completed.If freezing temperatures can be expected, check the cooling system for adequate protection against freezing. A 50/50 solution of Caterpillar permanent-type antifreeze and approved water will give protection below -29°C (-20°F).Generator Storage Procedure
When servicing or repairing electric power generation equipment:Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE1.Remove all fuses.Make sure the generator engine is stopped.Make sure all batteries are disconnected.Make sure all capacitors are discharged.Failure to do so could result in personal injury or death.Make sure residual voltage in the rotor, stator and the generator is discharged.
1DO NOT OPERATE tags, SEHS7332, are available from
When it is necessary to remove a component on an angle, remember that the capacity of an eyebolt is less as the angle between the supporting members and the object becomes less than 90 degrees. Eyebolts and brackets should never be bent and should only be loaded in tension.
Use a hoist to remove heavy components. Lift the engine by using an adjustable lifting beam. All supporting members (chains and cables) should be parallel to each other, and as near perpendicular as possible to the top of the object being lifted.To remove the engine ONLY, use the lifting eyes equipped with the engine. Lifting eyes are designed for the arrangement as sold and the end user is responsible for providing lifting devices. Alterations to lifting eyes and/or arrangement weight make the lifting eyes and devices obsolete. If you make alterations to the engine package as sold, you are responsible for providing adequate lifting devices.Engine Lifting With Generator (Package)
To remove the engine and generator together, refer to the lifting films located on the engine and generator package. See your Caterpillar dealer for information regarding fixtures and lifting devices for proper lifting of your engine package.Engine Storage
These instructions and recommendations will safeguard the possibility of engine damage if the engines are in storage for one year or less.If the engine will not be or has not been started for several weeks, the lubricating oil will drain from the cylinder walls and piston rings.If an engine remains out of service and its use is not immediately planned, special precautions should be taken. Rust can form on the cylinder liner surface, which will increase engine wear and may result in shorter engine life.To prevent this problem from becoming excessive, be sure all lubrication recommendations mentioned in the Maintenance Schedule are completed.After one year, a complete protection procedure must be followed if the engine is kept in storage longer.If it will be impossible to start the engine periodically, consult your Caterpillar dealer for instructions to prepare your engine for longer storage periods.If an engine remains out of service and its use is not immediately planned, special precautions should be taken. Refer to Storage Procedures For Caterpillar Products, SEHS9031 for more detailed information on engine storage.To prevent excessive engine wear:Be sure all lubrication recommendations mentioned in the Maintenance Schedule intervals chart are completed.If freezing temperatures can be expected, check the cooling system for adequate protection against freezing. A 50/50 solution of Caterpillar permanent-type antifreeze and approved water will give protection below -29°C (-20°F).Generator Storage Procedure
When servicing or repairing electric power generation equipment:Make sure the unit is off-line (disconnected from utility and/or other generators power service), and either locked out or tagged DO NOT OPERATE1.Remove all fuses.Make sure the generator engine is stopped.Make sure all batteries are disconnected.Make sure all capacitors are discharged.Failure to do so could result in personal injury or death.Make sure residual voltage in the rotor, stator and the generator is discharged.
1DO NOT OPERATE tags, SEHS7332, are available from
Have questions with 101601-7730?
Group cross 101601-7730 ZEXEL
Isuzu
101601-7730
1156012930
INJECTION-PUMP ASSEMBLY
6BD1
6BD1