Information injection-pump assembly
BOSCH
9 400 614 096
9400614096
ZEXEL
101431-4080
1014314080
ISUZU
8944781250
8944781250
Rating:
Service parts 101431-4080 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
9 400 614 096
9400614096
ZEXEL
101431-4080
1014314080
ISUZU
8944781250
8944781250
Zexel num
Bosch num
Firm num
Name
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
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
9.9
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
29.8
28.4
31.2
Max. variation between cylinders
%
0
-4.5
4.5
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
11.3
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
39.7
38.7
40.7
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
-
Rack position
7.8+-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.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_04
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
71
66
76
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
500+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
1.3
0.6
2
Timer adjustment_03
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)RACK LIMIT
(3)Set idle sub-spring
----------
K=14
----------
----------
K=14
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=4deg+-5deg b=23deg+-5deg c=32deg+-3deg
----------
----------
a=4deg+-5deg b=23deg+-5deg c=32deg+-3deg
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)
----------
aa=14deg
----------
a=(60deg)
Information:
1. Remove cylinder head bolts (1) and (2).
When lifting cylinder head, care must be taken to keep cylinder head level to prevent damage to the two cylinder head-to-spacer block dowels.
2. Lift the cylinder head off the spacer block. The approximate weight of the cylinder head is 236 Kg (520 Lbs.). The following steps are for the installation of the cylinder head.3. Thoroughly clean cylinder head and spacer block surfaces.4. Position the head gasket and the cylinder head onto the dowels in the spacer block. Lower the cylinder head onto the spacer block.5. Put engine oil on the threads of bolts (1) and (2), then install bolts. Tighten bolts (1) and (2) as follows:
Cylinder Head Tightening Sequencea. Tighten bolts 1 thru 26 in number sequence shown to a torque of 150 15 N m (110 11 lb.ft.).b. Tighten bolts 1 thru 26 in number sequence shown to a torque of 275 15 N m (200 11 lb.ft.).c. Retorque bolts 1 thru 26 in number sequence shown to 275 15 N m (200 11 lb.ft.).d. Tighten bolts 27 thru 33 in number sequence shown, to a torque of 34 7 N m (25 5 lb.ft.).End By:a. install valve cover baseb. install (ECU) fuel injectorsc. install rocker arm assemblies and push rodsd. adjust all the valve rocker arm clearances.e. install water outlet manifoldf. install exhaust manifold
When lifting cylinder head, care must be taken to keep cylinder head level to prevent damage to the two cylinder head-to-spacer block dowels.
2. Lift the cylinder head off the spacer block. The approximate weight of the cylinder head is 236 Kg (520 Lbs.). The following steps are for the installation of the cylinder head.3. Thoroughly clean cylinder head and spacer block surfaces.4. Position the head gasket and the cylinder head onto the dowels in the spacer block. Lower the cylinder head onto the spacer block.5. Put engine oil on the threads of bolts (1) and (2), then install bolts. Tighten bolts (1) and (2) as follows:
Cylinder Head Tightening Sequencea. Tighten bolts 1 thru 26 in number sequence shown to a torque of 150 15 N m (110 11 lb.ft.).b. Tighten bolts 1 thru 26 in number sequence shown to a torque of 275 15 N m (200 11 lb.ft.).c. Retorque bolts 1 thru 26 in number sequence shown to 275 15 N m (200 11 lb.ft.).d. Tighten bolts 27 thru 33 in number sequence shown, to a torque of 34 7 N m (25 5 lb.ft.).End By:a. install valve cover baseb. install (ECU) fuel injectorsc. install rocker arm assemblies and push rodsd. adjust all the valve rocker arm clearances.e. install water outlet manifoldf. install exhaust manifold