101603-4530 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034530 1156022700

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-4530 1016034530

ISUZU 1156022700 1156022700

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101603-4530 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 101603-4530 1016034530

ISUZU 1156022700 1156022700

Zexel num

Bosch num

Firm num

Name

101603-4530

1156022700 ISUZU

INJECTION-PUMP ASSEMBLY
6BD1T * 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 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 3.4 3.35 3.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.25 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.25 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.25 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.25 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.25 300.25

Injection quantity adjustment

Adjusting point -

Rack position 11.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 78.5 76.9 80.1

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 -

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.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.2)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 78.5 77.5 79.5

Fixing the lever *

Boost pressure kPa 15.3 15.3

Boost pressure mmHg 115 115

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.25

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 84.1 80.9 87.3

Fixing the lever *

Boost pressure kPa 15.3 15.3

Boost pressure mmHg 115 115

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.5

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 55.7 52.5 58.9

Fixing the lever *

Boost pressure kPa 15.3 15.3

Boost pressure mmHg 115 115

Injection quantity adjustment_06

Adjusting point I

Rack position 13+-0.5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 82 82 87

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position (R1-0.5) -0.8

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position (R1-0.5) -0.6

Boost pressure kPa 4.7 4.7 7.4

Boost pressure mmHg 35 35 55

Boost compensator adjustment_03

Pump speed r/min 600 600 600

Rack position R1-0.5

Remarks
Measure actual boost pressure.

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=C15 BCL=0.8+-0.1mm
----------

Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N3=800r/min C3=(6.4deg) t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1500r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=1.5--deg C2=6.4+-0.3deg R01=0/4load R02=4/4load

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=40deg+-5deg b=34deg+-3deg

Stop lever angle

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

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

0000001501 RACK SENSOR

(g) rack limit (h) Standard point (i) pump end face (j) Apply red paint. Rack sensor adjustment (154610-0420) 1. Rack limit adjustment (1)Fix the rack at the rack limit position Rl. (2)Attach shim (D) [shim thickness standard (17.5 - R1] to rod (C) and tighten nut (E). (3)Measure the distance X between the end face of the pump and the nut (E), and select a shim (D) so that X = 33-0.2mm. (4)Release the rack, mount the joint (B) and fix. (5)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack limit adjustment (amp-equipped type) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at No r/min. (3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (4)Apply red paint to both the joint (B) and the nut (F) join, and the joint (B) and the pump join.
----------
N=900r/min R=R1(11.2)mm VR=2+-0.01V
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

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

Information:

PARTS NEEDED
Qty
Part Number Description
*******Group 1*******
1 4716029 MTG GP-INJECTOR
1 ENGSOFTWARE ENGINE SOFTWARE
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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.
*******Group 2*******
1 4716029 MTG GP-INJECTOR
1 ENGSOFTWARE ENGINE SOFTWARE
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
If the engine software is not the latest version, update the Engine Software first.
If needed, update the engine software with the latest available in SIS Web.
For flash programming of the ECM software, refer to Troubleshooting "ECM Software - Install".
Ensure the appropriate steps have been followed when diagnosing a DEF injector failure. Refer to UENR0662.
If it is determined that replacement of DEF injector is required, refer to Disassembly and Assembly Manual - Diesel Exhaust Fluid Injector - Remove and Install.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-5000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job for Group 1
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-5000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.