Information injection-pump assembly
ZEXEL
101431-0240
1014310240
ISUZU
5156005421
5156005421
Rating:
Service parts 101431-0240 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-039-1
12.
Open Pre:MPa(Kqf/cm2)
11.8{120}
15.
NOZZLE SET
Cross reference number
ZEXEL
101431-0240
1014310240
ISUZU
5156005421
5156005421
Zexel num
Bosch num
Firm num
Name
101431-0240
5156005421 ISUZU
INJECTION-PUMP ASSEMBLY
C240 *
C240 *
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
105000-1650
Bosch type code
DN0SD2110
Nozzle holder
105081-3120
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-1.6-600
Outer diameter - inner diameter - length (mm) mm 6-1.6-600
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
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
A
Rack position
12.4
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
43
41.9
44.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
12
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
44
42.5
45.5
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
9
7.7
10.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
17.5+-0.
5
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
60
60
Fixing the lever
*
Timer adjustment
Pump speed
r/min
500+-50
Advance angle
deg.
0
0
0
Remarks
Start
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
-
Advance angle
deg.
6
6
6
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)At rack cap installation: R1
----------
K=10 R1=(17.5)mm
----------
----------
K=10 R1=(17.5)mm
----------
Speed control lever angle
F:Full speed
(1)Beginning of speed increase
(2)Fix idle side stopper bolt.
----------
----------
a=23deg+-5deg b=31deg+-5deg
----------
----------
a=23deg+-5deg b=31deg+-5deg
Information:
Belts, Hoses and Clamps
Inspect/Replace
Alternator and Fan Drive Belts
Inspect the condition and adjustment of alternator and accessory drive belts. Examine all drive belts for wear and replace if they show any signs of wear. Loose or worn pulley grooves cause belt slippage and low accessory drive speed. If belts are too loose, they vibrate enough to cause unnecessary wear on the belts and pulleys and possibly slip enough to cause overheating.If belts are too tight, unnecessary stresses are placed upon the pulley bearings and belts which might shorten the life of both.If one belt in a set requires replacement, always install a new matched set of belts. Never replace just the worn belt. If only the worn belt is replaced, the new belt will carry all the load, as it will not be stretched as much as the older belts. All the belts will fail in rapid succession.Adjust
1. Remove belt guard. Inspect the condition and adjustment of alternator belts and accessory drive belts, if equipped.2. To check the belt tension, apply 110 Newton (25 lb) force, perpendicular to the belt, midway between the driving and driven pulley. Measure the belt deflection. Correctly adjusted belts will deflect 15 to 20 mm (9/16 to 7/8 inch).If the belt does not require replacement or adjustment, install the belt guard. If the belt requires adjustment or replacement, do not install the belt guard. Perform the following procedure to adjust the belt tension.
(1) Typical belt assembly mounting bolt(2) adjusting nuts3. Loosen the mounting bolt (1) and the locknut on the adjusting bolt.4. Turn the adjusting nuts (2) to increase or decrease the belt tension.5. Tighten the adjusting bolt locknut. Tighten the mounting bolts.6. Install the belt guard.If new belts are installed, check the belt adjustment again after 30 minutes of engine operation.Hoses and Clamps
* Inspect all hoses for leaks due to cracking, softness and loose clamps. Replace hoses that are cracked or soft and tighten loose clamps.
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.
Check for the following:* End fittings damaged, leaking or displaced.* Outer covering chafed or cut and wire reinforcing exposed.* Outer covering ballooning locally.* Evidence of kinking or crushing of the flexible part of the hose.* Armoring embedded in the outer cover.A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new, constant torque hose clamp will help prevent these failures.Each installation application can be different depending on the type of hose, fitting material and anticipated
Inspect/Replace
Alternator and Fan Drive Belts
Inspect the condition and adjustment of alternator and accessory drive belts. Examine all drive belts for wear and replace if they show any signs of wear. Loose or worn pulley grooves cause belt slippage and low accessory drive speed. If belts are too loose, they vibrate enough to cause unnecessary wear on the belts and pulleys and possibly slip enough to cause overheating.If belts are too tight, unnecessary stresses are placed upon the pulley bearings and belts which might shorten the life of both.If one belt in a set requires replacement, always install a new matched set of belts. Never replace just the worn belt. If only the worn belt is replaced, the new belt will carry all the load, as it will not be stretched as much as the older belts. All the belts will fail in rapid succession.Adjust
1. Remove belt guard. Inspect the condition and adjustment of alternator belts and accessory drive belts, if equipped.2. To check the belt tension, apply 110 Newton (25 lb) force, perpendicular to the belt, midway between the driving and driven pulley. Measure the belt deflection. Correctly adjusted belts will deflect 15 to 20 mm (9/16 to 7/8 inch).If the belt does not require replacement or adjustment, install the belt guard. If the belt requires adjustment or replacement, do not install the belt guard. Perform the following procedure to adjust the belt tension.
(1) Typical belt assembly mounting bolt(2) adjusting nuts3. Loosen the mounting bolt (1) and the locknut on the adjusting bolt.4. Turn the adjusting nuts (2) to increase or decrease the belt tension.5. Tighten the adjusting bolt locknut. Tighten the mounting bolts.6. Install the belt guard.If new belts are installed, check the belt adjustment again after 30 minutes of engine operation.Hoses and Clamps
* Inspect all hoses for leaks due to cracking, softness and loose clamps. Replace hoses that are cracked or soft and tighten loose clamps.
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses. Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires. Inspect all lines, tubes and hoses carefully. Tighten all connections to the recommended torque.
Check for the following:* End fittings damaged, leaking or displaced.* Outer covering chafed or cut and wire reinforcing exposed.* Outer covering ballooning locally.* Evidence of kinking or crushing of the flexible part of the hose.* Armoring embedded in the outer cover.A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp. Due to extreme temperature changes, hose will heat set. Heat setting causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new, constant torque hose clamp will help prevent these failures.Each installation application can be different depending on the type of hose, fitting material and anticipated
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Group cross 101431-0240 ZEXEL
Isuzu
101431-0240
5156005421
INJECTION-PUMP ASSEMBLY
C240
C240