101601-8861 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016018861 1156017421


 

Information injection-pump assembly

ZEXEL 101601-8861 1016018861
ISUZU 1156017421 1156017421
101601-8861 INJECTION-PUMP ASSEMBLY
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Service parts 101601-8861 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:

101601-8861 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-8861 1016018861
ISUZU 1156017421 1156017421


Zexel num
Bosch num
Firm num
Name
101601-8861 
101601-8865 
 
1156017421  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   12.5
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   76.5 74.9 78.1
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   9.5+-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(12.5)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   76.5 75.5 77.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   I
Rack position   15.3+-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 101601-8861
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B25
----------

Speed control lever angle

Test data 101601-8861
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=42deg+-5deg b=(43deg)+-3deg

Stop lever angle

Test data 101601-8861
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101601-8861
(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=13deg
----------
a=(60deg)




Information:

Actual RackThe ECM's interpretation of the signal from the Rack Position Sensor which represents actual position of the rack.Actual Timing AdvanceDegrees of advance beyond static, as measured by the Timing Position Sensor (assumes that Timing Position Sensor is calibrated).After Market DeviceA device or accessory installed by the customer after the vehicle is delivered.Air-To-Air Aftercooler (ATAAC)A means of cooling intake air after the turbocharger, using ambient air for cooling. The intake air is passed through an aftercooler (heat exchanger) mounted in front of the radiator before going to the intake manifold.Alternating Current (AC)The direction of current flow changes (alternates) regularly and constantly.American Wire Gauge (AWG)A measure of the diameter (and therefor the current carrying ability) of electrical wire. The smaller the AWG number, the larger the wire.Before Top Dead Center (BTDC) or Before Top Center (BTC)The 180° of crankshaft rotation before the piston reaches Top Dead Center (normal direction of rotation).Boost Pressure SensorThis sensor measures inlet manifold air pressure and sends a signal to the ECM.Brushless Torque Motor (BTM)Solenoid used to move fuel rack servo spool valve and timing advance spool valve.Bypass CircuitA circuit, usually temporary, to substitute for an existing circuit, typically for test purposes.CalibrationAs used here, is an electronic adjustment of a sensor signal.Cruise Control RangeThe range that the cruise control can operate within. Usually limited to the speed range anticipated on the open road.CodeSee Diagnostic Code.Customer Specified ParameterA Parameter that can be changed and whose value is set by the customer. Protected by Customer Passwords.Data LinkAn electrical connection for communication with other microprocessor based devices that are compatible with the American Trucking Association and SAE Standard such as trip recorders, electronic dashboards, and maintenance systems. The Data Link is also the communication medium used for programming and troubleshooting with Caterpillar devices.Desired Rack Position ("Des Rack Pos" on ECAP)The rack setting calculated by the ECM as needed to attain or maintain the Desired RPM.Desired RPMAn input to the electronic governor within the ECM. The electronic governor uses inputs from the Throttle Position Sensor, Engine Speed/Timing Sensor and Customer Parameters to determine "Desired RPM".Desired Timing Advance ("Des Timing Adv" on ECAP)The injection timing advance calculated by the ECM as required to meet emission and performance specifications.Diagnostic CodeSometimes referred to as a "fault code", it is an indication of a problem or event in the PEEC III System.Diagnostic LampSometimes referred to as the "check engine light", it is used to warn the operator of the presence of an active diagnostic code.Digital Diagnostic Tool (DDT)A Caterpillar electronic service tool used for programming and for diagnosing the 3406B PEEC III system.Direct CurrentThe type of current where the only direction of current flow is consistently in one direction only.Duty CycleSame as Pulse Width Modulation.Electronic Control Analyzer Programmer (ECAP)A Caterpillar Electronic Service Tool used for programming and diagnosing a variety of electronic controls. Electronic Control Module (ECM)The engine control computer that provides power to the PEEC III electronics, monitors PEEC III inputs and acts as a governor to control engine rpm.Engine Speed

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Group cross 101601-8861 ZEXEL

Isuzu 

 
1156017420 
INJECTION-PUMP ASSEMBLY
6BG1
101601-8861  

101601-8865 
 
1156017421 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156017422 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156017423 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156017424 
INJECTION-PUMP ASSEMBLY
6BG1
9 400 614 674 
1156017425 
INJECTION-PUMP ASSEMBLY
6BG1
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