101601-7762 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016017762 1156013102


 

Information injection-pump assembly

ZEXEL 101601-7762 1016017762
ISUZU 1156013102 1156013102
101601-7762 INJECTION-PUMP ASSEMBLY
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Service parts 101601-7762 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-2830
3. GOVERNOR
4. SUPPLY PUMP 105220-5220
5. AUTOM. ADVANCE MECHANIS 105644-0170
6. COUPLING PLATE 105661-0421
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:

101601-7762 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-7762 1016017762
ISUZU 1156013102 1156013102


Zexel num
Bosch num
Firm num
Name
101601-7762 
101601-7763 
 
1156013102  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1 *

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 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   -
Rack position   12.7
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   78 76.4 79.6
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   260 260 260
Average injection quantity mm3/st.   8.1 6.8 9.4
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(12.7)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   78 77 79
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   I
Rack position   15+-0.5
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   92 92 100
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1350--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1300
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   2 1.5 2.5
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   4.5 4 5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-7762
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=78
----------

Speed control lever angle

Test data 101601-7762
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=42deg+-5deg b=(45deg)+-3deg

Stop lever angle

Test data 101601-7762
N:Pump normal S:Stop the pump.
----------

----------
a=25deg+-5deg b=40deg+-5deg

Timing setting

Test data 101601-7762
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)




Information:


Oil pressure should raise within nine seconds after the engine starts. If no oil pressure is indicated within ten seconds, the engine will shutdown. Investigate and correct the cause.
7. Do not apply load to the engine or increase engine rpm until the operating parameter readings indicate normal. Check all GSC display window readings during the warm-up period. Engine Starting Sequence
1. The GSC receives an engine start signal. The possible engine start signals are: a. ECS (Engine Control Switch) turned to MAN. START by the operatorb. The remote initiate contacts (IC) close while the ECS is in the AUTO position.2. The GSC checks the system before beginning the cranking sequence. The GSC checks that: a. No system faults are present.b. All previous faults have been reset (removed by turning the ECS to OFF/RESET).c. The engine is not already running.d. The service mode is not activated.3. The GSC activates the starting motor relay (SMR) and the run relay (RR).4. The GSC activates the fuel control relay (FCR) for the ETR fuel systems.5. The GSC cycle cranks (factory default is ten seconds crank and ten seconds rest) the engine until it starts or until the cycle crank time reaches the setpoint for total cycle crank time (overcrank).6. While the starting motor is cranking, the GSC shows the status of the relays on the relay status indicators of the lower display (i.e. K4, K5, K7 for ETR fuel systems).7. The GSC deactivates the starting motor relay (SMR) and activates the crank termination relay (CTR) when the engine speed reaches the setpoint for crank terminate speed (factory default is 400 rpm).8. The GSC activates the electronic governor (EG) relay when the oil pressure reaches the setpoint for low oil pressure at idle speed (factory default is 69 kPa [10 psi]). The EG relay signals the electronic governor (EG) to accelerate the engine to rated speed.9. The GSC shows: a. AC voltage, current, and frequency for one phase at a time on the upper display.b. System battery voltage, engine hours, engine rpm, oil pressure, and coolant temperature on the lower display.c. The relay status on the relay status indicators of the lower display. K1, K3, K5, K7 for ETR fuel systems.Starting From External Electrical Source
Make initial determination as to failure of engine to crank. Refer to special instruction SEHS7768 on use of 6V2150 Starting/Charging Analyzer Group.If the installation is not equipped with a back-up battery system, then it may be necessary to start the engine from an external electrical source. Many batteries thought to be unusable, are still rechargeable. Severely discharged maintenance free batteries might not fully recharge from the alternator alone after jump starting. The batteries must be charged to the proper voltage with a battery charger. Refer to Special Instruction, SEHS7633, Battery Test Procedure, available from your Caterpillar dealer, for complete testing and charging information.
Before attaching the booster cables, move ECS switch to OFF/RESET. Be sure the main power switch is in the OFF position before attaching the booster cables to

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Group cross 101601-7762 ZEXEL

Isuzu 

 
1156012481 
INJECTION-PUMP ASSEMBLY
6BF1
 
1156012491 
INJECTION-PUMP ASSEMBLY
6BF1
 
1156012501 
INJECTION-PUMP ASSEMBLY
6BF1
 
1156012930 
INJECTION-PUMP ASSEMBLY
6BD1
9 400 614 661 
1156013811 
INJECTION-PUMP ASSEMBLY
6QA1
9 400 614 662 
1156013820 
INJECTION-PUMP ASSEMBLY
6BB1
 
1156013100 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156013101 
INJECTION-PUMP ASSEMBLY
6BG1
101601-7762  

101601-7763 
 
1156013102 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156013103 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156013120 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156013121 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156013122 
INJECTION-PUMP ASSEMBLY
6BG1
9 400 614 663 
1156013123 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156013124 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156013500 
INJECTION-PUMP ASSEMBLY
6BD1
 
1156012820 
INJECTION-PUMP ASSEMBLY
6BG1
 
 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156012821 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156012822 
INJECTION-PUMP ASSEMBLY
6BG1
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