Information injection-pump assembly
BOSCH
9 400 610 012
9400610012
ZEXEL
101461-0471
1014610471
ISUZU
5156014401
5156014401
Rating:
Service parts 101461-0471 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-097-0
12.
Open Pre:MPa(Kqf/cm2)
11.8{120}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 610 012
9400610012
ZEXEL
101461-0471
1014610471
ISUZU
5156014401
5156014401
Zexel num
Bosch num
Firm num
Name
101461-0471
9 400 610 012
5156014401 ISUZU
INJECTION-PUMP ASSEMBLY
4BA1 * K
4BA1 * K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
1.95
1.9
2
Rack position
R=11.1
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.1
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
45.8
44.3
47.3
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
8.9+-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_03
Adjusting point
-
Rack position
16.5++
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
75
75
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
800
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
1
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
3
2.5
3.5
Timer adjustment_04
Pump speed
r/min
1750
Advance angle
deg.
5
5
6
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
P:Negative pressure
(1)Pneumatic governor
(2)Mechanical governor
(3)Acting negative pressure: P1
(4)Adjustment speed N1
(5)Beginning of idle sub spring operation: L1
(6)Injection quantity Q = Q1 or less
----------
N1=500r/min L1=9.1+-0.5mm Q1=3mm3/st
----------
----------
N1=500r/min L1=9.1+-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=12deg
----------
a=(100deg)
----------
aa=12deg
----------
a=(100deg)
Information:
Table 3
Injector Resistance Measurement
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding.
2 Disconnect the DEF injector from the applicable harness.
3 Inspect the connector for damage or debris (if damaged take photo)
4 Measure the temperature of the injector (aluminum body) C
5 Connect two 398-4987 connectors to the DEF injector. The connectors must be used to prevent damage to the DEF injector connector.
6 Measure the resistance of the DEF injector. Ohms
Table 4
Dosing Accuracy Test
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Follow the Testing and Adjusting, Aftertreatment SCR System Dosing - Test.
2 Remove the injector from the DPF outlet.
3 Take a photograph of the DEF injector mount on the DPF outlet and the tip of the DEF injector.
4 Install the injector on the beaker.
5 Run the DEF System Dosing Accuracy test through Cat ET.
6 Use the breaker to measure the amount of fluid from the dosing test. ml
7 Repeat the test to verify consistency. ml
8 Install the injector back onto the DPF outlet.
Illustration 2 g06068068
DEF Injector Resistance Measurement
Illustration 3 g06067706
Injector Mount on DPF (Outlet Sample Picture)
Illustration 4 g06067753
DEF Injector Tip (Sample Picture)
When troubleshooting requests the DEF quality check, DEF injector resistance measurement or Dosing Accuracy Test, please document results in the Tables shown above.
After completing troubleshooting and performing the Aftertreatment System Functional Test, download a new Product Status Report with all ECM's.
Table 5
Injector Failure Report
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Download "Product Status Report" (PSR) from the engine ECM and send to the email address in the instructions.
2 Download "Warranty Report" (WR) from the engine ECM and send to the email address in the instructions.
3 Take a picture of the injector part number / serial number.
4 Follow the correct TSG based on Table 1 and complete tables 2 through 4 when they apply.
5 Perform an "Aftertreatment System Functional Test".
6 Download "Product Status Report" (PSR) from the engine ECM and send to the email address in the instructions.
7 Submit "TIB Check List", "Product Status Reports", DEF injector deposits photographs, CEM deposit photographs, and DEF injector part number and serial number photograph to the email address in the instructions.
Fill out the Injector Failure Report and send all information including product status reports, warranty reports, DEF injector and mount photos, DEF injector part number and serial number and test results to the email address provided above.
Have questions with 101461-0471?
Group cross 101461-0471 ZEXEL
Isuzu
101461-0471
9 400 610 012
5156014401
INJECTION-PUMP ASSEMBLY
4BA1
4BA1