101601-7792 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016017792 1156012821


 

Information injection-pump assembly

ZEXEL 101601-7792 1016017792
ISUZU 1156012821 1156012821
101601-7792 INJECTION-PUMP ASSEMBLY
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Service parts 101601-7792 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-2800
3. GOVERNOR
4. SUPPLY PUMP 105220-4791
5. AUTOM. ADVANCE MECHANIS 105644-0180
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:

101601-7792 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-7792 1016017792
ISUZU 1156012821 1156012821


Zexel num
Bosch num
Firm num
Name
101601-7792 
101601-7793 
 
1156012821  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   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   -
Rack position   11.4
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   70.7 69.2 72.2
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   260 260 260
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.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.4)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   70.7 69.7 71.7
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   81 77.8 84.2
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   86 86 96
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1200--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1300
Advance angle deg.   2 1.5 2.5
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   5.5 5 6
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-7792
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=A38
----------

Speed control lever angle

Test data 101601-7792
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=42deg+-5deg b=35deg+-3deg

Stop lever angle

Test data 101601-7792
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101601-7792
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

17. Add coolant mixture if necessary to bring the coolant to within 13 mm (1/2 inch) below the bottom of the fill tube or the correct level on the sight glass, if equipped. Upon initial fill the sight gauge can indicate an incorrect coolant level. Be sure the coolant is to the bottom of the fill tube. Recheck the coolant level and fill the cooling system to the bottom of the fill tube if the system was low.
In cold weather, frequently check the specific gravity of the coolant solution to ensure adequate protection.If the engine is to be stored in, or shipped to an area with freezing temperatures, the cooling system must be either protected to the lowest expected outside temperature or drained completely to prevent damage. Always check your cooling system before operating your engine. Depending on load, failure to operate with thermostats could result in either an overheating or an excessive cooling condition.
18. Check the condition of the filler cap gasket (if equipped). If the gasket is damaged, discard the old filler cap and install a new filler cap. 19. Stop the engine and check the coolant to ensure it is at the proper level. Every 10,000 Hour Cleaning Procedure-Oil Cooler and Aftercooler Core
Caterpillar recommends that the oil cooler and aftercooler cores be removed, cleaned and pressure tested at Every 10,000 Hour overhaul time, or if a turbocharger failure has occurred, or if at any time the turbocharger develops an oil leak.1. Remove the core. Turn the core upside down to remove debris from the inlet.
Do not use caustic cleaners to clean the core. Caustic cleaners will attack the internal metals of the core and cause leakage.
2. Back flush internally with a solvent to loosen foreign substances and to remove oil. Caterpillar recommends the use of Caterpillar Hydrosolv 4165 or Hydrosolv 100 Liquid Cleaners. 3. Shake the core vigorously to eliminate any trapped debris. 4. Wash the core with hot, soapy water. Rinse thoroughly with clean water. 5. Dry the core with compressed air. Blow air in reverse direction of normal flow. Use all necessary safety equipment while using compressed air. 6. Inspect the system to ensure cleanliness and install the core. SR4 Generator
Make sure residual voltage in the rotor, stator and the generator is discharged.If this generator is to be connected to a utility electrical distribution system, it must be isolated from the distribution system by means of:a. Opening the main switch in the case of the generator temporarily connected to the system or,b. A double throw (transfer) switch in the case of a permanent connection to the system.Failure to do so could result in personal injury or death due to electrical shock. This warning does not apply when a generator and utility distribution system are designed and approved by the utility to run in parallel.
Before working inside the generator, make sure that the starting motor can not be activated by any automatic or manual signal.Electronic components in the regulator can be damaged during generator

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Group cross 101601-7792 ZEXEL

Isuzu 

 
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101601-7792  

101601-7793 
 
1156012821 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156012822 
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6BG1
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