101461-0431 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014610431 5156013512

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101461-0431 1014610431

ISUZU 5156013512 5156013512

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Service parts 101461-0431 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101046-8210

3. GOVERNOR 105542-3280

4. SUPPLY PUMP 105220-5071

5. AUTOM. ADVANCE MECHANIS 105622-1031

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:

101461-0150 as _

101461-0431 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101461-0431 1014610431

ISUZU 5156013512 5156013512

Zexel num

Bosch num

Firm num

Name

101461-0431

5156013512 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

Rack position
After adjusting injection quantity. R=10.6

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 11.95

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. 43.2 41.7 44.7

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. 67.4 67.4

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. 1.7 1.2 2.2

Timer adjustment_04

Pump speed r/min 1400

Advance angle deg. 4.2 3.7 4.7

Timer adjustment_05

Pump speed r/min 1750

Advance angle deg. 6.2 6.2 7.2

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=8.5+-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=(100deg)

Information:

Introduction
The problem that is identified below does not have a permanent solution. Until a permanent solution is known, use the solution that is listed below.Problem
A significant amount of HEUI pumps and injectors have been returned, but no cause of failure can be determined.Solution
Diagnostic procedures have been updated and have been incorporated into the following publications:
Special Instruction, REHS3819, "Procedure for Troubleshooting and Cleaning the Oil Rail System for the Hydraulic Electronic Unit Injector (HEUI)"
Troubleshooting, "Injection Actuation Pressure - Test"Note: These publications have been translated into Mandarin and Spanish.In addition, a new troubleshooting checklist is included with all service repair for HUEI pumps and HEUI injectors. The checklist is a summary of the diagnostic procedure steps to be confirmed before a suspect component is replaced. The checklist must be completed and returned with the suspect components in order to aid engineering to determine the cause of failure.Following the instructions step-by-step is critical in order to diagnose the failed component correctly. Do not skip steps in the procedures. Skipping steps in the procedure will lead to incorrect diagnosis of the problem.