Information injection-pump assembly
ZEXEL
101603-0530
1016030530
ISUZU
1156017751
1156017751
Rating:
Cross reference number
ZEXEL
101603-0530
1016030530
ISUZU
1156017751
1156017751
Zexel num
Bosch num
Firm num
Name
101603-0530
1156017751 ISUZU
INJECTION-PUMP ASSEMBLY
6BG1TC * K
6BG1TC * K
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
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
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
-
Rack position
13.8
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
89.9
88.3
91.5
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
9.7+-0.5
Pump speed
r/min
275
275
275
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(13.8)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
89.9
88.9
90.9
Basic
*
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.45
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
89.2
86
92.4
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_05
Adjusting point
C
Rack position
R-0.1
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
83.8
80.6
87
Fixing the lever
*
Boost pressure
kPa
20
20
Boost pressure
mmHg
150
150
Injection quantity adjustment_06
Adjusting point
D
Rack position
12.6
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
54.5
52.9
56.1
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
15+-0.5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
92
92
100
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
12.6
Boost pressure
kPa
2
2
4.7
Boost pressure
mmHg
15
15
35
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
13.1
Boost pressure
kPa
4.7
4.7
7.4
Boost pressure
mmHg
35
35
55
Boost compensator adjustment_03
Pump speed
r/min
550
550
550
Rack position
R1-0.1
Remarks
Measure actual boost pressure.
Measure actual boost pressure.
Timer adjustment
Pump speed
r/min
1325--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1275
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
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
(3)Boost compensator stroke: BCL
----------
T1=B04 BCL=(1.1)+-0.1mm
----------
----------
T1=B04 BCL=(1.1)+-0.1mm
----------
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=43deg+-5deg b=41deg+-3deg
----------
aa=35mm
----------
a=43deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
0000001501 RACK SENSOR
V1:Output voltage
Vf:Full side output voltage
F:Full-speed
I:Idle
(a) Speed lever
(B) Full side stopper bolt
(c) Nut
(d) Nut
(e) nut
(P) Potentiometer
1. Load sensor adjustment
(1)Apply voltage V to between the potentiometer (P)'s connector terminals (1) ~ (3) and measure the output voltage between (1) ~ (2).
(2)Move the speed lever (A) until it contacts the full side stopper bolt (B) and then turn the nut (D) to adjust the potentiometer (P)'s output voltage to Vf.
(3)Confirm that the speed lever (A) turns smoothly between idle and Full side, then fix using nut (E). (Tightening torque: 4.4~7N.m{0.5~0.7kgf.m})
(4)Move the speed lever (A) several times to contact full side stopper bolt (B) and confirm that the potentiometer (P) output voltage is Vf.
(5)Confirm that the speed lever (A) turns smoothly between idle and Full (b deg).
----------
V=DC24V Vf=16+-0.1V
----------
----------
V=DC24V Vf=16+-0.1V
----------
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)
----------
aa=13deg
----------
a=(60deg)
Information:
Before completing the attached Rework Procedure, review the safety actions in the Operation and Maintenance Manual for safety information and safe working practices before starting the rework.
If the head gasket has failed replace the head gasket and the fuel injection pump.
If the head gasket has not failed replace the fuel injection pump only.
The 483-2326 Fuel Injection Pump has revised injection timing to reduce the peak cylinder pressure in the engine. It is essential that the pump is installed as per the Disassembly and Assembly, "Fuel Injection Pump - Install - Delphi DP210" to achieve the desired fuel injection timing.
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all parts removed from dealer parts stock.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 5.5-hour job
For After failure, and additional 13.8 hours is allowed. A maximum of $100 will be allowed for machining of cylinder head face to achieve required surface finish after failure.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
If the head gasket has failed follow the rework procedure for both head gasket replacement and for fuel injection pump replacement
If the head gasket has not failed follow the rework procedure for fuel injection pump replacement only.
Head gasket replacement:
Confirm the head gasket has failed through removal of the cylinder head and visual inspection of the gasket. Remove cylinder head ? refer to Disassembly and Assembly, "Cylinder Head - Remove". Confirm head gasket has failed through visual inspection, as per the images shown in Image 1.1.1.
Clean the cylinder head face and the cylinder block face to remove any deposits on the gasket sealing surface using an appropriate cleaner. Do not use abrasive materials to remove the deposits during the cleaning process to ensure that the correct surface flatness is maintained.
Inspect cylinder head for flatness and distortion. Refer to Image 1.1.2 for surface finish. Refer to System Operation Testing and Adjusting, "Cylinder Head ? Inspect" for more information. Resurface the cylinder head if required as per Testing and Adjusting, "Cylinder Head ? Inspect".
Inspect cylinder block for surface finish on the top deck of the cylinder block. Refer to Image 1.1.2 for surface finish. If the cylinder block is within specifications, install a new 258-4946 Cylinder Head Gasket. If the block is not within specification, refer to Reuse And Salvage Guidelines, SEBF8076, "Specifications to Salvage Contact Surfaces of Cylinder Blocks" for more information.
Note: A 369-3705 Cylinder Head Gasket may be required, depending on reuse and salvage guidelines.
Follow Disassembly and Assembly, "Cylinder Head ? Install" with a new gasket as per above information.
Fuel injection pump replacement:
Follow Disassembly and Assembly, "Fuel Injection Pump - Remove - Delphi DP210". Do not reuse the fuel pump. Record removed fuel pump serial number in claim story. The fuel pump serial number is in the format "12345ABC".
Install the new
Have questions with 101603-0530?
Group cross 101603-0530 ZEXEL
Isuzu
101603-0530
1156017751
INJECTION-PUMP ASSEMBLY
6BG1TC
6BG1TC