101603-4561 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034561 1156023001


 

Information injection-pump assembly

ZEXEL 101603-4561 1016034561
ISUZU 1156023001 1156023001
101603-4561 INJECTION-PUMP ASSEMBLY
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Service parts 101603-4561 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-3261
3. GOVERNOR 105921-2550
4. SUPPLY PUMP 105210-4770
5. AUTOM. ADVANCE MECHANIS 105643-0190
6. COUPLING PLATE 105662-1170
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6941
11. Nozzle and Holder 1-15300-168-0
12. Open Pre:MPa(Kqf/cm2) 22.1(225)
13. NOZZLE-HOLDER 105030-3201
14. NOZZLE 105015-6410
15. NOZZLE SET

Include in #1:

101603-4561 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-4561 1016034561
ISUZU 1156023001 1156023001


Zexel num
Bosch num
Firm num
Name
101603-4561 
 
1156023001  ISUZU
INJECTION-PUMP ASSEMBLY
6SA1 * 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 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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.7 3.65 3.75
Beginning of injection position
Governor 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   11.6
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   80.2 78.6 81.8
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.   10.7 8.7 12.7
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(11.6)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   80.2 79.2 81.2
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.25
Pump speed r/min   1350 1350 1350
Average injection quantity mm3/st.   96.4 93.2 99.6
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1(11.6)
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   75 73.4 76.6
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   14.1+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   96.5 96.5 106.5
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1150--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1100
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1250
Advance angle deg.   3.1 2.6 3.6
Timer adjustment_04
Pump speed r/min   1350
Advance angle deg.   6 5.5 6.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-4561
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C53
----------

Speed control lever angle

Test data 101603-4561
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18deg+-5deg b=34deg+-3deg

Stop lever angle

Test data 101603-4561
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101603-4561
(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=14deg
----------
a=(40deg)




Information:


15Jun2015
(Revised 08Sep2015)
U-312
A-215
D-253
O-261
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN 10R4761 AND 10R4763 REMAN INJECTORS FROM DEALER PARTS STOCK
7750 PI70569
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
The information supplied in this service letter may not be valid after the termination date of this program.Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
This Revised Service Letter replaces the 15Jun2015 (Revised 12Aug2015) Service Letter. Changes have been made to Action Required and Service Claim Allowance. A request for photographs to be submitted with the claims story has been added.
TERMINATION DATE
30Sep2015
PROBLEM
Certain reman fuel injectors were mislabeled with an incorrect part number.
ACTION REQUIRED
Inspect all 10R4761 and 10R4763 Reman Fuel Injectors in dealer parts stock.
If an injector has a 12-character serial number listed in the table in Image 1, remove the part from dealer parts stock. Refer to the Parts Disposition. Include the Injector Serial Number in the Claim Story. Also, attach a photograph of the injector serial number with the claim story.
If an injector does not have a 12-character serial number listed in the table in Image 1, mark the package to indicate that the part has been inspected according to this program and return the part to dealer parts stock.
Image 2 identifies Reman Hydraulic Electronic Unit Injector (HEUI) product markings.
(1) 7-character Part Number
(2) 12-character Serial Number
(3) 4-digit Confirmation Code
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock. Include the Injector Serial Number(s) in the Claim Story. Also, attach a photograph of the injector serial number with the claim story.
PARTS DISPOSITION
NACD:
Hold all 10R4761 and 10R4763 Reman Fuel Injectors removed from dealer parts stock for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.
EAME, LACD, and APD:
Hold all 10R4761 and 10R4763 Reman Fuel Injectors removed from dealer parts stock for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork.
Contact Runge_Mark_H at Reman Product Support for a Parts Return Request (PRR).
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

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Isuzu 

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1156022658 
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101603-4561  
 
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INJECTION-PUMP ASSEMBLY
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INJECTION-PUMP ASSEMBLY
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INJECTION-PUMP ASSEMBLY
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1156022523 
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9 400 615 089 
 
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Isuzu 

9 400 615 089 
1156022524 
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