101431-0630 ZEXEL 9 400 610 297 BOSCH INJECTION-PUMP ASSEMBLY 9400610297 1014310630 5156010302

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 297 9400610297

ZEXEL 101431-0630 1014310630

ISUZU 5156010302 5156010302

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Buy INJECTION-PUMP ASSEMBLY 101431-0630 zexel genuine, new aftermarket engine parts with delivery

Service parts 101431-0630 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101043-9180

3. GOVERNOR 105520-3100

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 5-15300-039-1

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

13. NOZZLE-HOLDER 105081-3141

14. NOZZLE

105000-1650

15. NOZZLE SET

Include in #1:

101431-0630 as INJECTION-PUMP ASSEMBLY

106671-4771 as _

Cross reference number

BOSCH 9 400 610 297 9400610297

ZEXEL 101431-0630 1014310630

ISUZU 5156010302 5156010302

Zexel num

Bosch num

Firm num

Name

101431-0630

9 400 610 297

5156010302 ISUZU

INJECTION-PUMP ASSEMBLY
C240 * K 14BC PE4A,5A, PE

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 -

Rack position 12.4

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 33 31.4 34.6

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 11.8

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 36.5 35.5 37.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_03

Adjusting point -

Rack position 8.8+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 7 5.9 8.1

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

R:Rack position (mm) P:Negative pressure (1)Pneumatic governor (2)Torque control stroke (3)Beginning of idle sub spring operation: L1
----------
L1=6.5-0.5mm
----------

Stop lever angle

S:Stop the pump. (1)Rack position = at least aa
----------
aa=17.5mm
----------
a=(14.5deg) b=(30deg)

Timing setting

(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:

1. Disconnect fuel line (1) from the fuel transfer pump. Disconnect fuel line (2) from the fuel injection pump housing. Remove line (3) from the transducer module and aftercooler housing.2. Disconnect fuel injection lines (4) from the fuel injection pump housing.
Do not disconnect the air line from the air compressor until the air pressure is zero.
3. Loosen the bleed valves, and release the air pressure in the air tank.4. Remove air line (5). Remove coolant line (6). 5. Disconnect wiring harness from bracket (7). Disconnect wires at connectors (8).
Typical Example6. The weight of the fuel injection pump housing and rack actuator package is approximately 57Kg (125 lb.). Attach a hoist to the fuel injection pump housing and remove bolts (9).
Typical Example7. Remove two nuts (on shown) and two bolts (10). Remove bolt (11). Remove the fuel injection pump housing and rack actuator package (12).
Typical Example8. Remove O-ring seals (13) from the fuel injection pump housing.Install Fuel Injection Pump Housing And Rack Actuator Package
1. Attach a hoist to the fuel injection pump housing and rack actuator package (12). Be sure that the three O-ring seals are in position in the fuel injection pump housing. Install the fuel injection pump housing and rack actuator package on the timing gear housing. 2. Connect the wires at connectors (8).
Transducer Module3. Connect P5 to J5 connector, J11 to P11 connector, and P10 to J10 connector. 4. Install air line (5) and coolant line (6).5. Connect fuel injection lines (4) to the fuel injection pump housing. Tighten the fuel injection line nut to a torque of 40 7 N*m (30 5 lb.ft.) with tool (A).6. Connect the fuel line (1) to the fuel transfer pump. Connect fuel line (2) to the fuel injection pump housing. Install line (3) to the transducer module and aftercooler housing. For timing of the fuel injection pump, see Install Timing Advance Unit.End By:a. install timing advance unit