Information injection-pump assembly
ZEXEL
101602-7501
1016027501
ISUZU
1156028061
1156028061

Rating:
Service parts 101602-7501 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97022-096-1
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}
15.
NOZZLE SET
Include in #1:
101602-7501
as INJECTION-PUMP ASSEMBLY
Include in #2:
104748-1040
as _
Cross reference number
ZEXEL
101602-7501
1016027501
ISUZU
1156028061
1156028061
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
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
3.6
3.55
3.65
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
A
Rack position
9.3
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
49.3
48.3
50.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.1+-0.
5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
58.6
54.6
62.6
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
-
Rack position
7.7+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
9.4
8.1
10.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Set idle sub-spring
(3)Main spring setting
(4)Rack difference between N = N1 and N = N2
----------
K=16 N1=1200r/min N2=400r/min
----------
----------
K=16 N1=1200r/min N2=400r/min
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=24deg+-5deg b=120deg+-5deg
----------
----------
a=24deg+-5deg b=120deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=12deg+-5deg b=46deg+-5deg
----------
----------
a=12deg+-5deg b=46deg+-5deg
Timing setting

(1)Pump vertical direction
(2)Position of gear mark 'C' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=20deg
----------
a=(90deg)
----------
aa=20deg
----------
a=(90deg)
Information:
In this manual, specifications, service standards, adjustment procedures, disassembly procedures, inspection procedures, and reassembly procedures for the engine are shown in groups. The contents of each group are listed in the index and at the beginning of that group.For instructions on operation and periodic inspection, refer to the operation manual. For instructions on ordering replacement parts, refer to the parts catalog. For information on the engine's structure and function, refer to relevant training material.1. Items Shown in This Manual(1) Parts mentioned in the text and shown in the exploded views are numbered in their disassembly sequences.(2) Inspections to be performed during disassembly are shown in in the exploded views.(3) Service standards for inspection and repair operations are indicated at relevant places in the text and in a table in Group 2.(4) The sequences in which parts should be reassembled during reassembly operations are shown under reassembly drawings in this manner: .(5) The symbols and headings shown below are used in this manual to highlight particularly important and safety-critical instructions.
Indicates a condition that will cause death or serious injury if incorrect action is taken.
Indicates a condition that may cause death or serious injury if incorrect action is taken.
Indicates a condition that will cause engine damage or slight or moderate injury if incorrect action is taken.
Indicates a supplementary explanation or other important point.(6) With regard to tightening torques, points to which engine oil must be applied are labeled "Wet". Where there is no such indication, parts should be tightened in a dry condition.2. TerminologyTerms used in this manual are defined as follows:(1) Front and RearThe term "front" refers to the fan side of the engine, and the term "rear" applies to the flywheel side.(2) Left and RightThe terms "left" and "right" apply to the sides of the engine as seen from the flywheel.(3) Service Standards* Standard ValueThis term indicates a designed nominal dimension, the designed dimension of a single part, the standard clearance between two parts after assembly, or a standard performance value for an assembly.* LimitThis term indicates a value beyond which a part is no longer useable in terms of performance and strength and must be repaired or replaced.
Indicates a condition that will cause death or serious injury if incorrect action is taken.
Indicates a condition that may cause death or serious injury if incorrect action is taken.
Indicates a condition that will cause engine damage or slight or moderate injury if incorrect action is taken.
Indicates a supplementary explanation or other important point.(6) With regard to tightening torques, points to which engine oil must be applied are labeled "Wet". Where there is no such indication, parts should be tightened in a dry condition.2. TerminologyTerms used in this manual are defined as follows:(1) Front and RearThe term "front" refers to the fan side of the engine, and the term "rear" applies to the flywheel side.(2) Left and RightThe terms "left" and "right" apply to the sides of the engine as seen from the flywheel.(3) Service Standards* Standard ValueThis term indicates a designed nominal dimension, the designed dimension of a single part, the standard clearance between two parts after assembly, or a standard performance value for an assembly.* LimitThis term indicates a value beyond which a part is no longer useable in terms of performance and strength and must be repaired or replaced.