101461-0240 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014610240 5156010463

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101461-0240 1014610240

ISUZU 5156010463 5156010463

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Cross reference number

ZEXEL 101461-0240 1014610240

ISUZU 5156010463 5156010463

Zexel num

Bosch num

Firm num

Name

101461-0240

5156010463 ISUZU

INJECTION-PUMP ASSEMBLY
4BA1 * 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

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 1-3-4-2

Pre-stroke mm 1.95 1.9 2

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 12.9

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 46.3 44.8 47.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.9

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 47.3 45.3 49.3

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 9.7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10.5 9.1 11.9

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Timer adjustment

Pump speed r/min 500+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.7 0.2 1.2

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 2.3 1.5 3

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 4.4 3.9 4.9

Timer adjustment_05

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

Timer adjustment_06

Pump speed r/min -

Advance angle deg. 6 6 6

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK CAP: R1
----------
K=5 R1=(17.5)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=4deg+-5deg b=27deg+-5deg

Stop lever angle

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

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(100deg)

Information:

Table 1
Revision Summary of Changes
01 Added prefix S/N:8811-8299 Description Of Change: The new Diesel Exhaust Fluid (DEF) control unit software now used, has been released to improve the priming performance of DEF pumps in cold environments.Adaptable To:
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.The new and former part numbers are listed in Table 2.
Table 2
Required Parts
Qty Dosing Control Unit (DCU) Dosing Control Unit (DCU) Voltage New Part Number Part Name Former Part Numbers(1)
1 Restriction on Hazardous Substance (RoHS) (DCU) 24V 593-7031 Engine Software 567-5763
1 Restriction on Hazardous Substance (RoHS) (DCU) 12V 593-7030 Engine Software 567-5761
1 Non-Restriction on Hazardous Substance (RoHS) (DCU) 24V 593-7033 Engine Software 539-3577
1 Non-Restriction on Hazardous Substance (RoHS) (DCU) 12V 593-7032 Engine Software 539-3576
(1) The former part number listed is for reference only and may differ.The new software is available in the form of a flash file through the Caterpillar Service Information System (SIS). A newer part number may be available. SIS web only displays the latest available flash file.