101601-7943 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016017943 1156013173


 

Information injection-pump assembly

ZEXEL 101601-7943 1016017943
ISUZU 1156013173 1156013173
101601-7943 INJECTION-PUMP ASSEMBLY
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Service parts 101601-7943 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-2830
3. GOVERNOR 105931-1310
4. SUPPLY PUMP 105220-5220
5. AUTOM. ADVANCE MECHANIS 105644-0170
6. COUPLING PLATE 105661-0730
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-4821
11. Nozzle and Holder 1-15300-104-0
12. Open Pre:MPa(Kqf/cm2) 18.1(185)
13. NOZZLE-HOLDER 105031-3611
14. NOZZLE 105015-4130
15. NOZZLE SET

Include in #1:

101601-7943 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-7943 1016017943
ISUZU 1156013173 1156013173


Zexel num
Bosch num
Firm num
Name
101601-7943 
101603-0740 
 
1156013173  ISUZU
INJECTION-PUMP ASSEMBLY
6BG1 * K

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 101601-7943
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=78
----------

Speed control lever angle

Test data 101601-7943
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=42deg+-5deg b=(44deg)+-3deg

Stop lever angle

Test data 101601-7943
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101601-7943
(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

Commercial Diesel Engine Oils
The performance of commercial diesel engine oils are based on API categories. These API categories are developed to provide commercial lubricants for a wide variety of diesel engines that operate at various conditions.If Caterpillar DEO (multi-grade) is not used, the following commercial oils are recommended.* API CG-4 Preferred* API CF-4 AllowedAPI CG-4 oils are preferred for Caterpillar engines because of the fuel sulfur level. API CG-4 is the only oil category that evaluates oils with engine tests utilizing 0.05 percent sulfur fuel.The following explanations of these API categories can be used to make the proper choice of a commercial oil. CG-4: This is the newest oil category. CG-4 oils were primarily developed for diesel engines that are operating on 0.05 percent sulfur diesel fuel. All of the laboratory engine tests for this category were run with 0.05 percent sulfur diesel fuel. This category also defines oils that have superior soot discrepancy. CG-4 oils will provide improved viscosity control and improved crankcase cleanliness in applications where oil soot is a problem. CG-4 oils will provide improved viscosity control and improved crankcase cleanliness in applications where oil soot is a problem. CG-4 oils should also be used in engines that contain hydraulically actuated fuel injection pumps; these are the first oils to pass industry tests for foam control and viscosity shear loss. CG-4 oils must also pass recently developed tests for metals corrosion, and wear. CG-4 oils can be used in all Caterpillar engines where CF-4 oils are recommended. CF-4 oils service a wide variety of modern diesel engines. This oil classification was developed with 0.40 percent sulfur diesel fuel. The fuel used in the CF-4 tests represents the type of diesel fuels commonly available world wide. CF-4 oils provide improved piston deposit control and improved oil control when compared to the CE category oils. CF-4 oils also provide improved soot dispersancy compared to CD or CF category oils.Some commercial oils meeting these API specifications may require shortened oil change intervals as determined by close monitoring of oil condition and wear metals (Caterpillar S*O*S Oil Analysis Program preferred).Consult with your Caterpillar dealer for the latest oil recommendations or refer to the following Caterpillar Supplements: SEBU6250, SEBU6251, and SEBU6385.
Failure to follow these oil recommendations can cause shortened engine life due to deposits and or excessive wear.
Total Base Number (TBN) and Fuel Sulfur Levels For Caterpillar Direct Injection (DI) Diesel Engines
The TBN for a new oil is dependent on the sulfur level of the fuel used. For direct injection engines running distillate diesel fuel, the minimum new oil TBN (by ASTM D 2896) must be 10 times the fuel sulfur level, and the minimum TBN is 5 regardless of sulfur level, see the chart below.TBN vs Fuel Sulfur for Caterpillar DI Diesel Engines
Y=oil TBN shown by ASTM D2896. X=percent of fuel sulfur by weight. New oil TBN (1). Change oil when the used oil TBN limit (2) is reached.In areas where the fuel sulfur exceeds 1.5 percent, choose an

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