101601-8862 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016018862 1156017422

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-8862 1016018862

ISUZU 1156017422 1156017422

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Buy INJECTION-PUMP ASSEMBLY 101601-8862 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-8862 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 105661-0611

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:

101601-8862 as INJECTION-PUMP ASSEMBLY

101609-3012 as _

Cross reference number

ZEXEL 101601-8862 1016018862

ISUZU 1156017422 1156017422

Zexel num

Bosch num

Firm num

Name

101601-8862
101601-8865

1156017422 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 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 12.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 76.8 75.2 78.4

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(12.6)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 76.8 75.8 77.8

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

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C32
----------

Speed control lever angle

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

N:Pump normal S:Stop the pump.
----------

----------
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=13deg
----------
a=(60deg)

Information:

1. Remove fuel line (1) from the fuel transfer pump.2. Put caps in the fuel line openings to prevent fuel system contamination.3. Remove bolts (2), and remove fuel transfer pump (3). Check the condition of the O-ring seal on the fuel transfer pump. If necessary, make a replacement. The following steps are for installation of the fuel transfer pump.4. Be sure the O-ring seal is in position on the fuel transfer pump. Put clean engine oil on the O-ring seal.5. Put fuel transfer pump (3) in position, and install the bolts that hold it in place.6. Remove the caps from the fuel line openings, and install fuel line (1).Disassemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Remove seal (1) from the fuel transfer pump.
Cover (2) is under spring tension. Remove the bolts that hold cover (2) slowly to prevent injury.
2. Remove bolts (3) and cover (2) from the housing. 3. Remove seals (4) and valve (5) from cover (2). 4. Remove spring (6) from the piston.
Mark the orientation of valve (8) as to its location in the housing.
5. Remove washer (7), valve (8) and the seal from the housing. 6. Remove piston (9) and sleeve (10) from the housing. 7. Remove seal (11) from sleeve (12). 8. Remove guide and tappet assembly (13) from the housing. 9. Remove seal (14) from guide (15).
If tappet (17) or the guide are damaged or worn, they must be replaced as a unit.
10. Remove ring (16) from tappet (17) and the tappet from guide (15). 11. Remove the bolts and cover (18) from the housing. 12. Remove seal (19) from cover (18). 13. Remove valve (20) from the housing if necessary.Assemble Fuel Transfer Pump
1. Install valve (20) in housing as shown. 2. Put clean fuel on seal (19), and install it on cover (18).3. Install cover (18) on the housing.
The tappet and guide must be serviced as a unit.
4. Install tappet (17) in guide (15). Install ring (16) on tappet (17) to hold the tappet in the guide. 5. Put clean fuel on seal (14), and install it on guide and tappet assembly (13).6. Install guide and tappet assembly (13) in the housing as shown. 7. Put clean fuel on seal (11), and install it on sleeve (12).8. Install sleeve (12) in the housing. 9. Install piston (9) in the housing. 10. Install seal, valve (8) and washer (7) in the housing as shown. Be sure valve (8) is the correct position in the housing. 11. Install spring (6) in the piston. 12. Install valve (5) in cover (2) as shown.13. Put clean fuel on seals (4), and put them in position on cover (2).14. Install cover (2) on the housing. 15. Put seal (1) in position on the fuel transfer pump.16. Install the fuel transfer pump on the fuel injection pump housing.End By:a. install fuel transfer pump