101461-0281 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014610281 5156012320

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101461-0281 1014610281

ISUZU 5156012320 5156012320

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Service parts 101461-0281 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101046-8160

3. GOVERNOR 105542-3350

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105111-1190

11. Nozzle and Holder 5-15300-097-0

12. Open Pre:MPa(Kqf/cm2) 11.8{120}

13. NOZZLE-HOLDER 105041-1100

14. NOZZLE

105000-1650

15. NOZZLE SET

Include in #1:

101431-0360 as _

101461-0281 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101461-0281 1014610281

ISUZU 5156012320 5156012320

Zexel num

Bosch num

Firm num

Name

101461-0281

5156012320 ISUZU

INJECTION-PUMP ASSEMBLY
4BA1 *

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 11.75

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 43.2 41.2 45.2

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.6

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 43.9 42.4 45.4

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 8.4+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8.5 7.1 9.9

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position 16.5++

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 75 75

Fixing the rack *

Remarks
Excess fuel for starting.

Timer adjustment

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 1

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.5 1 2

Timer adjustment_04

Pump speed r/min 1400

Advance angle deg. 4 3.5 4.5

Timer adjustment_05

Pump speed r/min 1750

Advance angle deg. 6 6 7

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) P:Negative pressure (1)Pneumatic governor (2)Mechanical governor (3)Adjustment speed N1 (4)Beginning of idle sub spring operation: L1 (5)Acting negative pressure: P1 (6)Injection quantity Q = Q1 or less
----------
N1=500r/min L1=5.5+-0.5mm Q1=3mm3/st
----------

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=11deg
----------
a=(90deg)

Information:

Illustration 6 g06613192
Gray locking wedge removed from ECM connector
Remove gray locking wedge from 86-pin connector to provide access to release the DT Pins.Note: Circuit U937 to be removed from pin location number 24 and transferred to pin location 73.Note: Cloth tape will need to be removed to the split in the harness main bundle.Note: The U937 wire can then be routed into the opposite branch to gain enough free length to make the connection.Note: The U939 wire removed from pin location 73 has adequate length to be loaded into location 16.
Transfer and relocate the wires as detailed in Table 2.
Reinstall the locking wedge (B) when all wires have been transferred and relocated.
Illustration 7 g06613197
View of back of ECM connector with connector cover (D) removed
Apply cloth tape to both wire branches from the main bundle of wires up the branches to the harness strain relief strap location.
Illustration 8 g06613199
Connector cover (D) reinstalled with harness secured
(1) 3S-2093 Cable Strap
(D) Connector cover
Reinstall connector cover (D) and secure the harness branches using two cable straps (1).
Use caution when re-engaging the connector with the ECM.
Tighten allen head screw (A).Note: In certain cases, U937 may require lengthening to provide adequate strain relief when relocated in pin 73.Note: Refer to "Soldered Splice","Deutsch connector", or "Sealed Mechanical Splice" for the proper way to extend circuit U937.Soldered Splice
A soldered spliced can be made to extend the wire. Soldered connection will need to be insulated using an appropriately sized adhesive head shrink sleeve.
Illustration 9 g06613210
U937 removed
Remove U937 from ECM connector.
Cut pin off end of wire.
Strip wire 7.5 mm (0.30 inch).
Illustration 10 g06613213
Additional wire soldered to circuit U937
Solder to additional wire to extend U937 and install appropriate sized adhesive head shrink sleeve.
Install pin on end of U937.
Insert U937 into pin 73.
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connector.Deutsch connector
Table 3
Required Parts
Qty Part Number Part Name
1 115-8109 Wire Splice Note: The deutsch connector is a field serviceable alternative to permanent splices. It is made from the same high-quality silicone elastomer as used for the Deutsch connector seals and grommets. The splice body houses a contact retention system that secures a mated pair of contacts in a compact environmentally sealed unit. This splice can also be serviced with standard deutsch connector tools.
Illustration 11 g06613218
Deutsch connector section view
Illustration 12 g06613221
Deutsch connector splice installed
Illustration 13 g06613224
Sufficient strain relief for deutsch connector
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connectorSealed Mechanical Splice
Table 4
Required Parts
Qty Part Number Part Name
1 136-4877 Wire Splice Note: Sealed mechanical splices have head-shrinkable, environmentally sealed sleeves.
Illustration 14 g06613205
Sealed mechanical splice
Select appropriate splice size.
Strip wire 7.5 mm (0.3 inch).
Insert stripped wire into sealed mechanical splice.
Crimp sealed mechanical splice.
Apply heat to the crimped splice until tubing re-covers and adhesive flows.
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connector