101603-4573 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034573 1156022493

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-4573 1016034573

ISUZU 1156022493 1156022493

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101603-4573 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-4573 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4600

3. GOVERNOR 105931-5670

4. SUPPLY PUMP 105220-5550

5. AUTOM. ADVANCE MECHANIS 105644-0400

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4521

11. Nozzle and Holder 1-15300-213-1

12. Open Pre:MPa(Kqf/cm2) 18.1(185)

13. NOZZLE-HOLDER 105038-4001

14. NOZZLE

105017-0400

15. NOZZLE SET

Include in #1:

101402-0810 as _

101402-0830

101603-4573 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-4573 1016034573

ISUZU 1156022493 1156022493

Zexel num

Bosch num

Firm num

Name

101603-4573

1156022493 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-S * 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)
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 11.7

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 77.1 75.5 78.7

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(11.7)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 77.1 76.1 78.1

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. 88.7 84.7 92.7

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)Torque control stroke: L1 (3)RACK LIMIT
----------
T1=D07 L1=(1.5)mm
----------

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

0000001501 VARIABLE TORQUE CONTROL

N:Pump speed (r/min) R:Rack position (mm) Adjusting shim A Guide screw B (c) Nut (d) Nut (e) nut Torque control spring adjustment method for model responding to speed droop [Advice] Confirm that adjusting shim (A) thickness t = 1.3~1.5 mm is assembled before beginning adjustment. (1)Temporary idle lever position setting 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (2)Idling spring adjustment 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (3)Governor spring setting adjustment 1. Temporarily fix so that the governor shaft's guide screw B protrudes L2 (18 mm) from the end of the governor. 2. Set the control lever where it contacts the idle stopper bolt. 3. Increase the speed to Nh2+100 r/min or more. 4. Adjust using the two nuts C and D so that L1 = 0.3+0.5 mm and fix temporarily. 5. Adjust the protrusion L2 of the guide screw (B) so that the rack position at Nh1 is Rh1 and at Nh2 is Rh2. Then fix using the nut (E). 6. Further increase the speed and readjust the two nuts (C) and (D) so that there is no change in L1 until Nf+50 r/min. Then fix temporarily. [Advice] When L1 becomes smaller while speed is increasing to Nf+50 r/min, decrease speed by Nh2+100 r/min. Adjust so that L1 is even smaller, then again increase speed to Nf+50 r/min and confirm that L1 does not change. (4)Full load position setting 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083). (5)Torque control spring adjustment 1. Set the control lever so that it contacts the full speed stopper bolt. 2. At the specified speed Nf, adjust using the full speed stopper bolt so that governing begins, then fix temporarily. 3. Increase the speed and adjust using the two nuts (C) and (D) so that the rack position Rg can be obtained at the specified speed Ng. Fix temporarily. 4. Decrease the speed and confirm the governing point (the beginning of governing point) at the specified speed Nf. 5. Set the speed at Nf-50 r/min. 6. Measure the torque control stroke (L1) and adjust to the specified stroke (L1) using the shim (A). 7. After completing shim adjustment, repeat the above adjustment using the two nuts. 8. After confirming the specifications Nf and Ng, fix the two nuts (C) and (D). 9. In this condition, increase the speed and confirm that R = 0 can be obtained. (6)Full speed lever position setting 1. Set the control lever so that it contacts the full speed stopper bolt. 2. At the specified speed Nu, adjust using the full speed stopper bolt so that governing begins, then fix temporarily 3. Increase the speed and confirm that the specified rack position Ru can be obtained. 4. Adjust using the full speed stopper bolt so that governing begins at the specified speed Nf, then fix. 5. Confirm that the result is the same as that in '(5) Torque control spring adjustment.' 6. Confirm that the control lever operating angle is within the specifications. (7)Rack limit adjustment 1. Refer to the RLD type governor service manual (Publication no. EE13E-11083).
----------

----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at the No. 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(60deg)

Information:

ACTION REQUIRED
Refer to the attached Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-2000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Use the procedures on the following pages in order to apply the updates to your machine.
- Park the machine on a firm, level surface.
- Fully retract and lower the boom.
- Place the travel select lever in the (N) NEUTRAL position.
- Apply Park Brake.
- Shut the engine off and remove the key from the MAIN switch located inside the engine compartment.
- Properly disconnect the battery.
- Place a Do Not Operate Tag on both the ignition key-switch and the steering wheel, stating that the machine should not be operated.
- Allow the engine area and antifreeze to cool down.
- Remove the cab rear cover.
- Use all applicable safety precautions while working on, around or under any machinery.
1. Locate DEF coolant supply hose (1) and DEF coolant return hose (2) on the engine. Refer to Image1.2.1.
Image1.2.1
2. Trace the routing of DEF coolant supply hose (1) on the engine to DEF coolant control valve (3) located in the middle of the frame. Refer to Image1.2.1 and 1.3.1.
Image1.3.1
3. Trace the routing of DEF coolant return hose (2) from the engine to DEF tank (4) located behind rear of the cab. Refer to Image1.2.1 and 1.4.1.
Image1.4.1
4. If the routing of DEF coolant supply hose (1) and DEF coolant return hose (2) are found to be correct, remount the cab rear cover and place the unit back in service.
5. If the routing of DEF coolant line (1) and DEF coolant return hose (2) are found to be incorrect, please continue the next steps to correct the DEF coolant line installation.
6. Remove all the cable straps that securing the two DEF coolant lines together or to other hoses. Refer to Image1.6.1. Some of the parts have been removed for clarity. Cut the 610cm of 5P-0767 Hose into two pieces: 330cm and 280cm.
Image1.6.1
7. Taking all precautions to minimize and contain any antifreeze spillage, disconnect DEF coolant supply hose (1) from DEF coolant control valve (3) and from the engine side DEF coolant supply port. The hose will not be reused. Retain the hose clamps for reuse. Refer to Image1.2.1 and 1.4.1.
8. Disconnect DEF coolant return hose (2) from DEF coolant tank (4) and from the engine side DEF coolant return port. The hose will not be reused. Retain the hose clamps for reuse. Refer to Image1.2.1 and 1.6.1.
9. Identify the new DEF coolant supply hose. It is the shorter