101603-4821 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016034821 1156023711


 

Information injection-pump assembly

ZEXEL 101603-4821 1016034821
ISUZU 1156023711 1156023711
101603-4821 INJECTION-PUMP ASSEMBLY
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Service parts 101603-4821 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-3530
3. GOVERNOR 105921-2690
4. SUPPLY PUMP 105210-4930
5. AUTOM. ADVANCE MECHANIS 105643-0500
6. COUPLING PLATE 105662-1051
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6941
11. Nozzle and Holder 1-15300-168-1
12. Open Pre:MPa(Kqf/cm2) 22.1{225}
13. NOZZLE-HOLDER 105030-3201
14. NOZZLE 105015-6410
15. NOZZLE SET

Include in #1:

101603-4821 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101603-4821 1016034821
ISUZU 1156023711 1156023711


Zexel num
Bosch num
Firm num
Name
101603-4821 
101603-4822 
 
1156023711  ISUZU
INJECTION-PUMP ASSEMBLY
6SA1 *

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 71.8 78.2
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   1120
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1250
Advance angle deg.   2.7 2.2 3.2
Timer adjustment_03
Pump speed r/min   1350
Advance angle deg.   5.6 5.1 6.1
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-4821
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C53
----------

Speed control lever angle

Test data 101603-4821
F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=67.5mm
----------
a=18deg+-5deg b=34deg+-3deg

Stop lever angle

Test data 101603-4821
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101603-4821
(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:


Cat does not warrant the quality or performance of non-Cat fluids.
Do NOT mix brands or types of SCA. Do NOT mix SCAs and extenders.Failure to follow the recommendations can result in shortened cooling system component life.
Use Only Approved SCAs. Conventional coolants require the maintenance addition of SCA throughout their expected life. Do NOT use an SCA with a coolant unless specifically approved by the coolant supplier for use with their coolant. It is the responsibility of the coolant manufacturer to ensure compatibility and acceptable performance.Failure to follow the recommendations can result in shortened cooling system component life.
Follow the maintenance information provided in the “Coolant and General Maintenance Recommendations” section in this Special Publication.Select a commercial diesel engine antifreeze coolant that meets all the requirements given in Table 1. The table contains the requirements for coolant to meet the published service intervals.The provided requirements are applicable to finished coolants and not for the concentrates. When concentrated coolant/antifreeze is mixed, Cat recommends mixing the concentrate with distilled water or with deionized water. If distilled water or deionized water is not available, water which has the required properties may be used. For the water properties, refer to this Special Publication, "General Coolant Information" article.Coolant/antifreezes for heavy-duty applications that meet "ASTM D6210" do not require treatment with SCA at the initial fill. Use the recommended 1:1 or higher concentration with recommended water. Treatment with SCA is required on a maintenance basis.The SCA manufacturer is responsible for ensuring the SCA is compatible with water meeting the “Caterpillar Minimum Acceptable Water Quality Requirements” as found in this Special Publication, and "ASTM D6210-08, Table X1.1". The coolant manufacturer and the SCA manufacturer are responsible to ensure that the products will not cause cooling system harm.Do not mix brands or types of coolants with different brands or types of SCA or extender.If using non Cat coolants, refer to the coolant manufacturer for information on a compatible SCA.Treat the compatible commercial coolant with 3 to 6 percent Cat SCA by volume. Maintain a 3 to 6 percent concentration level of SCA in the cooling system. For more information, refer to this Special Publication, "Conventional Coolant/Antifreeze Cooling System Maintenance" article.
Table 1
Technical Requirements for Commercial Diesel Engine Antifreeze Coolants
Specifications ASTM D6210-08
Additional Requirements Silicon: 100 ppm minimum to 275 ppm maximum
Nitrites: maintained at 1200ppm (70 grains/US gal) minimum to 2400 ppm (140 grains/US gal) maximum
Cat SCA at 3 to 6 percent (if Cat SCA is added)
Maintenance ASTM D6210-08 Add compatible SCA at maintenance intervals
Clean and flush the cooling system at drain intervals

Have questions with 101603-4821?





Group cross 101603-4821 ZEXEL

Isuzu 

 
1156023280 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156023281 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156023282 
INJECTION-PUMP ASSEMBLY
6BG1
 
1156022151 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156022152 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156022153 
INJECTION-PUMP ASSEMBLY
6BG1-TC
9 400 615 097 
1156022154 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156023710 
INJECTION-PUMP ASSEMBLY
6SA1
101603-4821  

101603-4822 
 
1156023711 
INJECTION-PUMP ASSEMBLY
6SA1
9 400 615 098 
1156023712 
INJECTION-PUMP ASSEMBLY
6SA1
 
1156022741 
INJECTION-PUMP ASSEMBLY
6BD1T
9 400 615 099 
1156022742 
INJECTION-PUMP ASSEMBLY
6BD1-T
 
1156023032 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023033 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023034 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023035 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023036 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156023037 
INJECTION-PUMP ASSEMBLY
6BG1-TC
9 400 615 100 
 
INJECTION-PUMP ASSEMBLY
6BG1-TC

Isuzu 

9 400 615 100 
1156023038 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156023720 
INJECTION-PUMP ASSEMBLY
6BG1TC
 
1156023721 
INJECTION-PUMP ASSEMBLY
6BG1TC
9 400 615 101 
 
INJECTION-PUMP ASSEMBLY
6BG1-TC

Isuzu 

9 400 615 101 
1156023722 
INJECTION-PUMP ASSEMBLY
6BG1-TC
 
1156024300 
INJECTION-PUMP ASSEMBLY
6BG1N
 
1156024301 
INJECTION-PUMP ASSEMBLY
6BG1N
 
1156024310 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156022602 
INJECTION-PUMP ASSEMBLY
6BG1S
9 400 615 102 
1156022603 
INJECTION-PUMP ASSEMBLY
6BG1-S
 
1156024320 
INJECTION-PUMP ASSEMBLY
6BG1S
 
1156024321 
INJECTION-PUMP ASSEMBLY
6BG1S
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