101431-4010 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014314010 8944286451


 

Information injection-pump assembly

ZEXEL 101431-4010 1014314010
ISUZU 8944286451 8944286451
101431-4010 INJECTION-PUMP ASSEMBLY
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Service parts 101431-4010 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101043-9170
3. GOVERNOR 105410-8480
4. SUPPLY PUMP 105220-4742
5. AUTOM. ADVANCE MECHANIS 105621-0370
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105151-1451
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 11.8(120)
13. NOZZLE-HOLDER 105081-3141
14. NOZZLE 105000-1650
15. NOZZLE SET

Include in #1:

101431-4010 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101431-4010 1014314010
ISUZU 8944286451 8944286451


Zexel num
Bosch num
Firm num
Name
101431-4010 
101431-4011 
 
8944286451  ISUZU
INJECTION-PUMP ASSEMBLY
C240 * 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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-3-4-2
Pre-stroke mm   2.25 2.2 2.3
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   12.6
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   41.3 39.7 42.9
Max. variation between cylinders %   0 -4 4
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   12
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   43 42 44
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_03
Adjusting point   -
Rack position   7.6+-0.5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   8 6.9 9.1
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   800
Advance angle deg.   1 0.5 1.5
Timer adjustment_03
Pump speed r/min   1050
Advance angle deg.   2 1.2 2.7
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   4.5 3.9 4.9
Timer adjustment_05
Pump speed r/min   1750
Advance angle deg.   6 5.5 6.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101431-4010
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK CAP: R1
----------
K=13 R1=(17.5)mm
----------

Speed control lever angle

Test data 101431-4010
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=70mm
----------
a=23deg+-5deg b=30deg+-5deg

Stop lever angle

Test data 101431-4010
N:Pump normal S:Stop the pump. (1)At delivery
----------

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

Timing setting

Test data 101431-4010
(1)Pump vertical direction (2)Gear mark Z for the No. 4 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(60deg)




Information:

Step 8. Check Signal Voltage At ECMA. Install the 40-Pin Breakout 'T' at the ECM Connector (J4/P4).B. Measure the voltage between Fuel Pressure, Pin 39 and Sensor Return Analog, Pin 35. The signal voltage should correspond to the observed fuel pressure reading shown in Table A. OK: The Fuel Pressure Signal is reaching the ECM. If Step 3 found that the ECM is not reading fuel pressure correctly, then the ECM is defective. Replace the ECM. Stop. NOT OK: The signal was good at the sensor but did not reach the ECM. Repair the wiring harness between Fuel Pressure Sensor and the ECM. Stop.P227: Retarder Enable Signal Test
The "Retarder Enable" signal is provided by the ECM to indicate that conditions are acceptable for an engine retarder to operate. Operation of the retarder is inhibited during undesirable engine operating conditions (such as while the engine is being fueled).With the Cruise Control ON/OFF Switch in the OFF position, the retarder is enabled under the following conditions:* engine rpm is greater than 950 rpm and* driver's foot is off the throttle pedal and the clutch pedalWith the Cruise Control ON/OFF Switch "ON", the operation of the retarder is also controlled through the customer parameter "Engine Retarder Mode". Programming the parameter to "COAST" allows retarding with the service brakes applied, but allows the engine to coast with no retarding after they are released. Programming the parameter to "LATCH" allows retarding with the service brake applied and keeps the retarder latched on after the service brakes are released (until engine rpm drops below 950 rpm or the driver presses the throttle or clutch pedal).The Retarder Enable Signal should be 15% Duty Cycle (nominal) to indicate that the retarder is enabled and 85% Duty Cycle (nominal) to indicate that it is disabled. The remainder of the engine retarder circuit is supplied by the OEM. In typical installations, the Retarder Enable signal isused by a separate Brake Control Module, which then energize the retarder solenoids. An "Engine Brake On" Switch is also typically connected to the Brake Control Module, and must be ON before the brake will operate. Step 1. Inspect Connectors And Wiring HarnessInspect the Vehicle Connector (J7/P7) and the ECM Connector (J4/P4) connections and wiring between, being sure to:* Check Connector lock rings.* Perform 10 pound pull test on each pin or wire.* Inspect wiring for damage or abrasion.* Inspect connectors for damage or corrosion. Refer to P-201: Inspecting Electrical Connectors for details. Repair any damage, then continue with the next step.Step 2. Verify Throttle Position And Clutch Switch InputsA. Use P-303: Throttle Position Sensor Adjustment procedure to verify correct adjustment of the throttle pedal. The "Throttle Position Signal" must be less than 7% at low idle, to perform the remainder of this test procedure.B. Use P-215: Service Brake And Clutch Switch Test, to verify correct adjustment and operation of the Clutch Pedal Switch. Clutch Switch Status must be OFF, with foot off the clutch, to perform the remainder of this test procedure.Step

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