Information injection-pump assembly
ZEXEL
101601-8661
1016018661
ISUZU
1156016803
1156016803
Rating:
Service parts 101601-8661 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-105-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-8661
1016018661
ISUZU
1156016803
1156016803
Zexel num
Bosch num
Firm num
Name
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 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
3.4
3.35
3.45
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
10.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
72
70.4
73.6
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
-
Rack position
9.6+-0.5
Pump speed
r/min
290
290
290
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(10.6)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
72
71
73
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.
76.5
73.3
79.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.25
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
46.5
43.3
49.7
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1050--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
(1300)
Advance angle
deg.
1
0.5
1.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT: RAL
----------
T1=B51 RAL=13.5+0.2mm
----------
----------
T1=B51 RAL=13.5+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=40deg+-5deg b=32deg+-3deg
----------
aa=35mm
----------
a=40deg+-5deg b=32deg+-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 No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(60deg)
----------
aa=16deg
----------
a=(60deg)
Information:
Cruise Control On/Off Input Circuit
The cruise control (CC) and power take-off (PTO) ON/OFF input is an ordinary switch. With this switch in the ON position, it is possible to "activate" the cruise control or power take-off mode if other ECM programmed conditions are met.With this switch "open" (or OFF), the input line to the ECM will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the ECM will go to 0 volts (ground).Cruise Control Set/Resume Input Circuit
The cruise control and power take-off set/resume is provided by a three position switch. The switch is used to SET vehicle speed or engine rpm. The function of each position of the switch is as follows:1) CENTER POSITION, the set/resume switch is "open" and all inputs are inactive.2) SET POSITION, after the switch is moved to the SET position and released, the ECM will maintain the existing engine rpm (determining vehicle speed) when the switch was released. If the engine is held in the SET position, the ECM will gradually increase engine rpm (determining vehicle speed) until the switch is released.3) RESUME POSITION, if cruise is deactivated by application of the clutch or service brake, and the switch is then moved to the RESUME position and released, the cruise (PTO) mode is reactivated to the last setting. If the switch is held in the RESUME position, the ECM will gradually decrease engine rpm (determining vehicle speed) until the switch is released.With this switch "open" (or OFF), the input line to the ECM will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the ECM will go to 0 volts (ground).Vehicle Switches Input Circuits
The brake switch is used to deactivate the cruise or PTO modes when the vehicle service brakes are applied. The brake switch is also used to activate the retarder enable output if the service brakes are applied while in cruise mode.The clutch switch is used to deactivate the cruise or PTO modes when the clutch pedal is pressed. The clutch switch is used to DEACTIVATE the retarder enable circuit.With this switch "open" (or OFF), the input line to the ECM will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the ECM will go to 0 volts (ground).Fuel Pressure Input Circuit
Fuel pressure is monitored after the filter by the fuel pressure sensor which is located on the fuel filter housing. The 5 Volt DC operating voltage for this sensor is supplied by the ECM. The output of the fuel pressure sensor is a .5 to 4.5 Volts DC signal. The voltage is dependent upon fuel pressure and is interpreted by the ECM as fuel pressure. If fuel pressure is less than 445 kPa (65 psi) at rated rpm, the "check engine" light is turned on.Engine Electrical System
The electrical system can have three separate circuits: the charging circuit, the starting circuit and the low amperage circuit. Some of the electrical system components are
The cruise control (CC) and power take-off (PTO) ON/OFF input is an ordinary switch. With this switch in the ON position, it is possible to "activate" the cruise control or power take-off mode if other ECM programmed conditions are met.With this switch "open" (or OFF), the input line to the ECM will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the ECM will go to 0 volts (ground).Cruise Control Set/Resume Input Circuit
The cruise control and power take-off set/resume is provided by a three position switch. The switch is used to SET vehicle speed or engine rpm. The function of each position of the switch is as follows:1) CENTER POSITION, the set/resume switch is "open" and all inputs are inactive.2) SET POSITION, after the switch is moved to the SET position and released, the ECM will maintain the existing engine rpm (determining vehicle speed) when the switch was released. If the engine is held in the SET position, the ECM will gradually increase engine rpm (determining vehicle speed) until the switch is released.3) RESUME POSITION, if cruise is deactivated by application of the clutch or service brake, and the switch is then moved to the RESUME position and released, the cruise (PTO) mode is reactivated to the last setting. If the switch is held in the RESUME position, the ECM will gradually decrease engine rpm (determining vehicle speed) until the switch is released.With this switch "open" (or OFF), the input line to the ECM will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the ECM will go to 0 volts (ground).Vehicle Switches Input Circuits
The brake switch is used to deactivate the cruise or PTO modes when the vehicle service brakes are applied. The brake switch is also used to activate the retarder enable output if the service brakes are applied while in cruise mode.The clutch switch is used to deactivate the cruise or PTO modes when the clutch pedal is pressed. The clutch switch is used to DEACTIVATE the retarder enable circuit.With this switch "open" (or OFF), the input line to the ECM will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the ECM will go to 0 volts (ground).Fuel Pressure Input Circuit
Fuel pressure is monitored after the filter by the fuel pressure sensor which is located on the fuel filter housing. The 5 Volt DC operating voltage for this sensor is supplied by the ECM. The output of the fuel pressure sensor is a .5 to 4.5 Volts DC signal. The voltage is dependent upon fuel pressure and is interpreted by the ECM as fuel pressure. If fuel pressure is less than 445 kPa (65 psi) at rated rpm, the "check engine" light is turned on.Engine Electrical System
The electrical system can have three separate circuits: the charging circuit, the starting circuit and the low amperage circuit. Some of the electrical system components are