101603-7810 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016037810 1156027860

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-7810 1016037810

ISUZU 1156027860 1156027860

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Buy INJECTION-PUMP ASSEMBLY 101603-7810 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-7810 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4881

3. GOVERNOR 105931-8740

4. SUPPLY PUMP 105220-5930

5. AUTOM. ADVANCE MECHANIS 105644-0440

6. COUPLING PLATE 105661-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5095

11. Nozzle and Holder 1-15300-266-4

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

13. NOZZLE-HOLDER 105048-3862

14. NOZZLE

105017-1111

15. NOZZLE SET

Include in #1:

101603-7810 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5324 as _

Cross reference number

ZEXEL 101603-7810 1016037810

ISUZU 1156027860 1156027860

Zexel num

Bosch num

Firm num

Name

101603-7810
101603-7811

1156027860 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-TC1 * 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 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)
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

Rack position
After adjusting injection quantity. R=A

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 13.2

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 95.7 94.1 97.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

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 *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.2)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 95.7 94.7 96.7

Basic *

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 96.7 93.5 99.9

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 55)

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 77 73.8 80.2

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

Injection quantity adjustment_06

Adjusting point D

Rack position R2-0.85

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 61.9 58.7 65.1

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 93 93 125

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position R2-0.85

Boost pressure kPa 3.3 3.3 6

Boost pressure mmHg 25 25 45

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R2(R1-0. 55)

Boost pressure kPa 14.7 14.7 14.7

Boost pressure mmHg 110 110 110

Timer adjustment

Pump speed r/min (1170)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1325

Advance angle deg. 1.5 1 2

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=F36 BCL=0.85+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=39.5deg+-5deg b=(37deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

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

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------

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=10deg
----------
a=(60deg)

Information:

This Program must be administered as soon as possible.When reporting the repair, use "PI1419" as the Part number and "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code.Exception:If the repair is done after failure, use "PI1419" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
This Revised Service Letter replaces the August 9, 1999 (Revised August 1999) Service Letter. Changes have been made to the Parts Needed, Action Required, Service Claims Allowances, and Owner Notification Letter.
Problem
The rivet that retains the governor link to the rack bar can become loose.A loose rivet can result in rivet wear.This rivet wear can result in poor engine performance symptoms including: low idle instability, engine dying from low idle, or engine surge under operational loads.
Affected Product
316 MUI Truck (9GK45180-70157, 9YN3132-4777, 7HJ1000-2798, 2FR394-7343, 9LN5573-8734, 7HS316-1821, 7JL439-1046, 7AG2806-6496, 5RM1263-4201, 3RJ1653-3237)
Parts Needed
1 - 180-7956 Clamp Group1 - 1192940 Gasket (Valve Cover)1 - N/A Dealer seal (For resealing fuel setting)Other Parts And Supplies (As Needed)
1 - 180-7951 Bushing Gp- 4C-9500 or 122-3781 Quick Cure Primer- 154-9731 Thread Locking Compound Greenfield Industries:
042-1023-20 (ball nose " Bur)046-1013-20 (egg shaped " Bur)Call #888-434-4311
Action Required
Customer Services for nearest Greenfield Dealer
Use Special Instruction REHS0601, "Inspection and Modification of the 4P-9048 Rack Control Assembly and the 102-7459 Rack Control Assembly", to work the Affected Product.
Below is an overview of the procedure to be completed using Special Instruction REHS0601
Figure 1. Lever Assembly...The rivet to be inspected is indicated by the arrow.
Figure 2. 180-7951 Bushing Group. This group can replace a "worn" rivet and eliminate the need to replace the entire Rack Control Assemblies where the engine installation permits.
Figure 3. 180-7956 Clamp Group. This group can be used to strengthen a tight rivet or a rack with a replaced rivet.Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)Copy Of Owner Notification For U.S. And Canadian Owners