101601-7961 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016017961 1156014071


 

Information injection-pump assembly

ZEXEL 101601-7961 1016017961
ISUZU 1156014071 1156014071
101601-7961 INJECTION-PUMP ASSEMBLY
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Service parts 101601-7961 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-0850
3. GOVERNOR 105931-1351
4. SUPPLY PUMP 105220-4781
5. AUTOM. ADVANCE MECHANIS 105612-3180
6. COUPLING PLATE 105661-0681
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6051
11. Nozzle and Holder 1-15300-134-0
12. Open Pre:MPa(Kqf/cm2) 18.1(185)
13. NOZZLE-HOLDER 105030-3201
14. NOZZLE 105015-5720
15. NOZZLE SET

Include in #1:

101601-7961 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-7961 1016017961
ISUZU 1156014071 1156014071


Zexel num
Bosch num
Firm num
Name
101601-7961 
 
1156014071  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1 * K
101601-7961 
 
1156014072  ISUZU
INJECTION-PUMP ASSEMBLY
6BD1 A * 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   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
Rack position
Point A
  R=A
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   10.7
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   52.5 50.9 54.1
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   9.8+-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.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(10.7)
Pump speed r/min   950 950 950
Average injection quantity mm3/st.   52.5 51.5 53.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.3
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   59 55.8 62.2
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.15
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   58.3 55.1 61.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   15.3+-0. 5
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   80 80 85
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1100--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1050
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1300
Advance angle deg.   1.2 0.7 1.7
Timer adjustment_04
Pump speed r/min   1600
Advance angle deg.   3 2.5 3.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-7961
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=97
----------

Speed control lever angle

Test data 101601-7961
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=34deg+-5deg b=43deg+-3deg

Stop lever angle

Test data 101601-7961
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101601-7961
(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=15deg
----------
a=(60deg)




Information:


Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components. Allow the engine to cool down before stopping. Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.
Emergency Stopping
Emergency shutoff controls are for EMERGENCY use ONLY. DO NOT use Emergency shutoff devices or controls for normal stopping procedure.
Make sure that any external system components that have been operating to support engine operation are secured after any stop.Emergency Stop Buttons
Emergency Stop Button, shown mounted on a junction box.Emergency stops may be made by pushing the Emergency Stop Button located on the junction box (if equipped). Both the Button and the air inlet shutoff (if equipped) require resetting before the engine will start.Manual Stopping
A manual shutoff shaft is provided to override the governor control. The shaft will move the fuel control linkage to the FUEL OFF position. Refer to the Model Views for the engine location of the shaft. The engine may be stopped by using the shaft and the Woodward Actuator (if equipped) or the Mechanical Governor (if equipped).
Typical Woodward Actuator Control Lever.If equipped with a Woodward Actuator, move the control lever to the FUEL OFF position.
Typical Mechanical Governor ControlIf equipped with a Mechanical Governor Control, move the control to the FUEL OFF position.Hold the lever at the FUEL OFF position until the engine stops.Air Shutoff (If Equipped)
Some engines are equipped with an air shutoff, located between the aftercooler and the turbocharger. If equipped with an air shutoff lever, move the lever to the OFF position.Manual Stop Procedure
There may be several ways to shut off your engine. Make sure the shutoff procedures are understood. Use the following general guidelines for stopping the engine.1. Disengage any driven equipment or remove the load from engine.2. Allow the engine to run at rated speed for five minutes.3. Run the engine at 1/2 rated speed for two to three minutes.4. Reduce the engine speed to low idle for 30 seconds.Check the crankcase oil level during the engine idle. Read the LOW IDLE side of the dipstick. Maintain the oil level between the ADD and FULL marks.5. Shut the engine off by turning the start/stop switch to the stop or off position.After Stopping the Engine
* Check the crankcase oil level. Maintain the oil level between the ADD and FULL marks in the FULL RANGE zone on the dipstick.* Repair any leaks, perform minor adjustments, tighten loose bolts, etc.* Note the service hour meter reading. Perform periodic maintenance as instructed in the Maintenance Schedule.* Fill the fuel tank to prevent accumulation of moisture in the fuel. Do not overfill.
Only use antifreeze/coolant mixtures recommended in the Cooling System Specifications of this manual. Failure to do so can cause engine damage.
* Allow the radiator and engine jacket water system to cool. Check the coolant level. Maintain the cooling system to 13 mm (1/2 inch) from bottom of the fill pipe.If freezing temperatures are expected, check the coolant for proper antifreeze protection. The cooling system

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