101603-4701 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034701 1156021811


 

Information injection-pump assembly

ZEXEL 101603-4701 1016034701
ISUZU 1156021811 1156021811
101603-4701 INJECTION-PUMP ASSEMBLY
Rating:
17
Buy INJECTION-PUMP ASSEMBLY 101603-4701 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 101603-4701 1016034701
ISUZU 1156021811 1156021811


Zexel num
Bosch num
Firm num
Name
101603-4701 
101603-4703 
 
1156021811  ISUZU
INJECTION-PUMP ASSEMBLY
6SA1T *

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)
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   12.5
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   107.2 105.6 108.8
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   290 290 290
Average injection quantity mm3/st.   9.9 7.9 11.9
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(12.5)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   107.2 106.2 108.2
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.4
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   100.6 97.4 103.8
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   98.5 98.5 108.5
Fixing the lever   *
Timer adjustment
Pump speed r/min   950--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   900
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1250
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-4701
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C68
----------

Speed control lever angle

Test data 101603-4701
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18deg+-5deg b=30deg+-3deg

Stop lever angle

Test data 101603-4701
N:Pump normal S:Stop the pump. (1)Stopper bolt setting
----------

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

0000001501 ACS

Test data 101603-4701
(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=900r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1(12.5)mm Rb=(R1-0.2)mm Pa=77.3+-2.7kPa(580+-20mmHg) Pb=65.3+-0.7kPa(490+-5mmHg) Q1=107.2+-1cm3/1000st Q2=101.9+-1.6cm3/1000st

Timing setting

Test data 101603-4701
(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=11deg
----------
a=(40deg)




Information:


TECHNICAL INFORMATION BULLETIN March 05, 2003
Articulated Truck
Cold Planer
Landfill Compactor
Excavator
Motor Grader
Off-Highway Truck/Tractor
Quarry Truck
Track-Type Tractor
Underground Articulated Truck
Wheel Loader
Wheel Tractor
Wheel Tractor-Scraper D30C (05A)
PM-565 (3TK)
PM-565B (8GS)
836 (7FR)
5110B (AAA)
24H (7KK)
69D (9SS, 9XS)
73D (1GW)
769D (BBB, 5SS, 5TR)
773D (7ER, 7CS)
771D (BCA, 6JR, 6YS)
775D (6KR, 8AS)
D10R (3KR)
D9R (ABK, ACL, 7TL, 8BL)
AD40 II (1YZ)
AD45 (BKZ)
AE40 II (BLW, 1ZZ)
988F II (2ZR)
990 II (4FR)
834B (7BR)
844 (2KZ)
631E II (1AB1446-Up, 1NB)
631E (1AB1-1445)
631G (AWK)
633E II (2PS)
637E II (1FB532-Up)
637E (1FB1-531)
637G (AXT)
651E (4YR)
657E (5YR, 6PR, 6TR, 7KR)
Component Code: 1901SUBJECT: Flashing New Software When Electronic Control Module (ECM) or Injectors Are Replaced
PROBLEM:
There have been dealer reports of engine ECMs locking up when new software is being installed. Dealer staff may see a message on the service tool such as: "The ECM is not responding to the service tool. Error code 864256". The flashing will typically hang up after 88% complete. When you reconnect, ET will not be able to communicate. Messages you typically get: "The communication adapter was unable to connect to the ATA data link. Error # 441. The requested protocol is not compatible with an existing datalink." You may also see: "The software file and the ECM are not compatible. Process aborted ? Error Code: 147456."
The two new software part numbers are:
222-XXXX (needed when a 172-0802 ECM is replaced by a 156-7156 ECM)
214-YYYY (needed when new-style injectors are installed)
SOLUTION:
If you are considering performing Product Support Program PS50424 on one of the above-listed machines, you may want to delay the program until new software is released. New software will be released in the near future to resolve this issue. Once the flashfiles are in SIS Web, a follow-up TIB will announce the new software?s availability.
On machine engines that have an older ECM that fails (145-7808 or 172-0802), the current 156-7172 production ECM will be needed for parts service. This will require using one of the 222-XXXX flashfiles. To minimize the possibility of locking-up the ECM, the dealer service staff can do one of the following:
Flash the ECM before traveling to the job site. This will require a By-Pass harness.
Flash the ECM on the engine. A By-Pass harness is recommended. If a By-Pass harness is used, disconnect the machine wiring harness before flashing the engine ECM. Dealers report that this method reduces the number of lock-ups.
If the dealer does not have a By-Pass harness, one will have to be purchased or assembled. If a new 129-2018 Wiring Harness Assembly (By-Pass) is purchased, modifications are necessary. Instructions on how to modify a By-Pass harness (Method 1: Modify a By-Pass Harness) and assemble a By-Pass harness (Method 2: Assemble a By-Pass Harness) appear later in this TIB.
Note: When flashing engine ECMs, always download the file from SIS Web to the computer?s hard drive. The service person should then upload (flash) to the ECM from the computer?s hard drive. For a listing of all models affected and the current software, refer to REHS1385-02, "Introduction of New 3408E and 3412E Hydraulic Electronic Unit Injectors".
Method 1: Modify a By-Pass Harness
When flashing an on-engine ECM with the current files, Caterpillar recommends the use

Have questions with 101603-4701?





Group cross 101603-4701 ZEXEL

Isuzu 

 
1156021810 
INJECTION-PUMP ASSEMBLY
6SA1T
101603-4701  

101603-4703 
 
1156021811 
INJECTION-PUMP ASSEMBLY
6SA1T
 
1156021812 
INJECTION-PUMP ASSEMBLY
6SA1T
 
1156021813 
INJECTION-PUMP ASSEMBLY
6SA1-T
 
1156022081 
INJECTION-PUMP ASSEMBLY
6QA1
 
1156022460 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022461 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022462 
INJECTION-PUMP ASSEMBLY
6BG1N
 
1156022470 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022471 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022472 
INJECTION-PUMP ASSEMBLY
6BG1N
9 400 615 094 
1156022473 
INJECTION-PUMP ASSEMBLY
6BG1-N
 
1156022480 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022481 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022482 
INJECTION-PUMP ASSEMBLY
6BG1N
 
1156023100 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156023101 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156023102 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156023103 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156023104 
INJECTION-PUMP ASSEMBLY
6BG1N
 
1156023105 
INJECTION-PUMP ASSEMBLY
6BG1-N
 
1156023106 
INJECTION-PUMP ASSEMBLY
6BG1-N
9 400 615 095 
 
INJECTION-PUMP ASSEMBLY
6BG1-N

Isuzu 

9 400 615 095 
1156023107 
INJECTION-PUMP ASSEMBLY
6BG1-N
 
1156022550 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022551 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022552 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022553 
INJECTION-PUMP ASSEMBLY
6BG1-S
 
 
INJECTION-PUMP ASSEMBLY
6BG1
 
 
INJECTION-PUMP ASSEMBLY
6BG1S
 
 
INJECTION-PUMP ASSEMBLY
6BG1S
9 400 615 096 
 
INJECTION-PUMP ASSEMBLY
6BG1-S
 
1156023270 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156023271 
INJECTION-PUMP ASSEMBLY
6BG1
F 019 Z20 470 
1156023272 
INJECTION-PUMP ASSEMBLY
6BG1
F 019 Z20 470 
1156023273 
INJECTION-PUMP ASSEMBLY
6BG1
Back to top