Information injection-pump assembly
BOSCH
9 400 614 090
9400614090
ZEXEL
101431-0830
1014310830
ISUZU
5156012431
5156012431
Rating:
Service parts 101431-0830 INJECTION-PUMP ASSEMBLY:
1.
_
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
BOSCH
9 400 614 090
9400614090
ZEXEL
101431-0830
1014310830
ISUZU
5156012431
5156012431
Zexel num
Bosch num
Firm num
Name
101431-0830
9 400 614 090
5156012431 ISUZU
INJECTION-PUMP ASSEMBLY
C240 K
C240 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)
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
Rack position
R=12
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
Pump speed
r/min
1900
1900
1900
Average injection quantity
mm3/st.
42.4
41.4
43.4
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
8+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
7.8
6.7
8.9
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
-
Rack position
-
Pump speed
r/min
1900
1900
1900
Average injection quantity
mm3/st.
42.4
41.9
42.9
Remarks
Smoke setting: 3.2 kPa {400 mmAq}
Smoke setting: 3.2 kPa {400 mmAq}
Timer adjustment
Pump speed
r/min
550
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
1.1
0.6
1.6
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
3.2
2.7
3.7
Timer adjustment_04
Pump speed
r/min
1950
Advance angle
deg.
6.5
6
7
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)Beginning of idle sub spring operation: L1
(5)Injection quantity Q = Q1 or less
----------
L1=8.6+0.3mm Q1=3mm3/st
----------
----------
L1=8.6+0.3mm Q1=3mm3/st
----------
Speed control lever angle
B:When boosted
N:Normal
(1)Rack position = aa
----------
aa=18mm
----------
a=12deg+-5deg b=2.5deg+-5deg
----------
aa=18mm
----------
a=12deg+-5deg b=2.5deg+-5deg
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=12deg
----------
a=(60deg)
----------
aa=12deg
----------
a=(60deg)
Information:
2. Turn the crankshaft until two pistons are at bottom center.3. Remove bolts (1) and the bearing caps. Push the rods and pistons up until the rings are out of the cylinder liners. 4. Remove pistons (2) and connecting rods from the cylinder liners.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.Install Pistons And Connecting Rod Assemblies
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners. 2. Use tool (A), and install piston (2) and the connecting rod in the cylinder liner. Be sure the number on the tab groove side of the connecting rod is on the opposite side from the camshaft.3. Install the bearing cap on the connecting rod with the number on the side of the bearing cap on the same side and same number as on the connecting rod.4. Put 2P2506 Thread Lubricant on the threads of the bolts. Install the bolts, and tighten them to a torque 90 8 N m (65 6 lb ft.). Put a mark on the bolts and tighten the bolts an additional 90 5°.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.End By:a. install oil pumpb. install cylinder head assemblyDisassemble And Assemble Pistons And Connecting Rod Assemblies
Start By:a. remove pistons and connecting rod assemblies 1. Remove bearings (2) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) and tool (A).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove piston rings (5) from the piston with tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See, Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No. SMHS7295.5. Heat connecting rod (4) in an oven to a temperature of 177° to 260° C (350° to 500° F). Never use a direct flame or heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of tooling (C). Put a new rod pin bearing (6) on the adapter of tooling (C). The old bearing is pushed out by tooling (C) as the new ring is installed.7. Use tooling (C) to push the new bearing into the connecting rod until the push adapter of tooling (C) make full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 50.830 0.008 mm (2.0012 .0003 in.).9. Check the clearance between the ends of the piston rings. See the topic, Pistons and Rings in the Specifications manual.10. Install the oil ring spring in the oil ring groove of the piston. The oil ring is to be installed over the spring with the oil ring end gap 180° from the oil ring spring joint.11. Install the oil ring on the piston with tool (B).12. Install the second (intermediate) piston ring with the side
1. Put clean engine oil on piston rings, connecting rod bearings and cylinder liners. 2. Use tool (A), and install piston (2) and the connecting rod in the cylinder liner. Be sure the number on the tab groove side of the connecting rod is on the opposite side from the camshaft.3. Install the bearing cap on the connecting rod with the number on the side of the bearing cap on the same side and same number as on the connecting rod.4. Put 2P2506 Thread Lubricant on the threads of the bolts. Install the bolts, and tighten them to a torque 90 8 N m (65 6 lb ft.). Put a mark on the bolts and tighten the bolts an additional 90 5°.5. Do Steps 1 through 4 for the remainder of the pistons and connecting rods.End By:a. install oil pumpb. install cylinder head assemblyDisassemble And Assemble Pistons And Connecting Rod Assemblies
Start By:a. remove pistons and connecting rod assemblies 1. Remove bearings (2) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) and tool (A).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove piston rings (5) from the piston with tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See, Use Of Piston Pin Bearing Removal And Installation Tools, Special Instructions, Form No. SMHS7295.5. Heat connecting rod (4) in an oven to a temperature of 177° to 260° C (350° to 500° F). Never use a direct flame or heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of tooling (C). Put a new rod pin bearing (6) on the adapter of tooling (C). The old bearing is pushed out by tooling (C) as the new ring is installed.7. Use tooling (C) to push the new bearing into the connecting rod until the push adapter of tooling (C) make full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 50.830 0.008 mm (2.0012 .0003 in.).9. Check the clearance between the ends of the piston rings. See the topic, Pistons and Rings in the Specifications manual.10. Install the oil ring spring in the oil ring groove of the piston. The oil ring is to be installed over the spring with the oil ring end gap 180° from the oil ring spring joint.11. Install the oil ring on the piston with tool (B).12. Install the second (intermediate) piston ring with the side
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Group cross 101431-0830 ZEXEL
Isuzu
101431-0830
9 400 614 090
5156012431
INJECTION-PUMP ASSEMBLY
C240
C240