101603-0773 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016030773 1156018573

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-0773 1016030773

ISUZU 1156018573 1156018573

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Cross reference number

ZEXEL 101603-0773 1016030773

ISUZU 1156018573 1156018573

Zexel num

Bosch num

Firm num

Name

101603-0773

1156018573 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1 * K

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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 11.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73.1 71.5 74.7

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 275 275 275

Average injection quantity mm3/st. 8 6.7 9.3

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(11.5)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73.1 72.1 74.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point I

Rack position 14+-0.5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 90 90 98

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=D27
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=45mm
----------
a=21.5deg+-5deg b=35deg+-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:

PARTS NEEDED
Qty
Part Number Description
1 4609257 INJECTOR AS-DEF
1 5398400 SFWR GP-A1000
1 BULK_COOLANT COOLANT (MAX 1 GALLON)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Ensure that all safety information, warnings, and instructions are read and understood before any operation or any maintenance procedures are performed. Refer to the Operation and Maintenance Manual "Safety Section".
1. Remove the existing DEF injector assembly and replace with a new 460-9257 DEF Injector Assembly. Refer to UENR4468, Disassembly and Assembly, to remove and install the new DEF Injector Assembly.
2. Update the engine software. Reflash the engine controller (ECM) with the 539-8400 Software Group or latest available on SIS Web.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3001-5000 hrs,
37-60 mo 100.0% 0.0% 0.0% 0.0% 0.0% 100.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.