101603-4572 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034572 1156022492

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-4572 1016034572

ISUZU 1156022492 1156022492

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Cross reference number

ZEXEL 101603-4572 1016034572

ISUZU 1156022492 1156022492

Zexel num

Bosch num

Firm num

Name

101603-4572
101603-4573

1156022492 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1S *

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 3.6 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 11.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 74.8 73.2 76.4

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(11.6)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 74.8 73.8 75.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 87.3 83.3 91.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 93 93 101

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1275

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C90
----------

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=38deg+-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=12deg
----------
a=(60deg)

Information:

28Oct2019
U-642
A-510
D-558
O-556
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING OR REPLACING THE 506-8793 FAST FILL DEF NOZZLE IN DEALER PARTS STOCK, DEALER TOOL INVENTORY, OR CUSTOMER TOOL INVENTORY
7750 PI70777
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.
TERMINATION DATE
31Jan2020
PROBLEM
The existing 506-8793 Fast Fill DEF Nozzles can get stuck while filling DEF and will not kick out when the DEF tank is full.
ACTION REQUIRED
Dealer Parts Stock:
Inspect all 506-8793 Fast Fill DEF Nozzles in dealer parts stock. If a 506-8793 Fast Fill DEF Nozzle is equipped with a blue twist engagement handle, then remove the part from dealer part stock.
Dealer Tool Inventory and/or Customer Tool Inventory:
Inspect all 506-8793 Fast Fill DEF Nozzles in dealer tool inventory. If a 506-8793 Fast Fill DEF Nozzle is equipped with a blue twist engagement handle, then replace the fast fill DEF nozzle with a 584-9979 Fast Fill DEF Nozzle.
Dealers should check their records of customers who have purchased one or more of the 506-8793 Fast Fill DEF Nozzles. If necessary, inspect all 506-8793 Fast Fill DEF Nozzles in customer tool inventory. If a 506-8793 Fast Fill DEF Nozzle is equipped with a blue twist engagement handle, then replace the fast fill DEF nozzle with a 584-9979 Fast Fill DEF Nozzle.
Image1
SERVICE CLAIM ALLOWANCES
Dealer Parts Stock:Submit one claim for all parts removed from dealer parts stock.Dealer Tool Inventory and/or Customer Tool Inventory:One 584-9979 Fast Fill DEF Nozzle is allowed for each 506-8793 Fast Fill DEF Nozzle removed from service that is equipped with a blue twist engagement handle.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.