Information injection-pump assembly
ZEXEL
101431-4120
1014314120
ISUZU
8943254660
8943254660
Rating:
Service parts 101431-4120 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
ZEXEL
101431-4120
1014314120
ISUZU
8943254660
8943254660
Zexel num
Bosch num
Firm num
Name
101431-4120
8943254660 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
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
16.4+-0.
1
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)Idle sub spring setting: L1.
----------
K=5 L1=5.5-0.5mm
----------
----------
K=5 L1=5.5-0.5mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Set the pump speed at aa
(2)Set the pump speed at bb.
----------
aa=750r/min bb=900r/min
----------
a=23deg+-5deg b=6deg+-5deg c=0deg+-5deg d=32deg+-3deg
----------
aa=750r/min bb=900r/min
----------
a=23deg+-5deg b=6deg+-5deg c=0deg+-5deg d=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:
Start By:a. remove oil panb. remove underframe 1. Remove bolts (1) that hold main bearing cap (2) in place and remove main cap (2).2. Remove the bearing half from the cap.
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both the crankshaft and block.
3. Remove the upper half of main bearings (3) as follows:a. Turn the crankshaft until tool (A) can be installed in the crankshaft journal. Install tool (A).b. Turn the crankshaft in the direction which will push the upper main bearing out, tab end first.c. Check the condition of the bearings. (See Guideline For Reusable Parts, Main And Connecting Rod Bearings, Form No. SEBF8009 and SEBD0531). The following steps are for the installation of the crankshaft main bearings. Put clean engine oil on the main bearings for the assembly. Also, be sure the tabs on the back side of the main bearings fit in the grooves of the main bearing caps and cylinder block.4. Clean the surfaces in the cylinder block for the main bearings. Use tool (A), and install new upper halves of main bearing (bearings with the oil hole) in the cylinder block. Do not put oil on the back of the bearing.5. Clean the surface of the main bearing caps for the main bearings. Install the new lower halves of the main bearings in the main caps. Do not put oil on the back of the bearing. Main bearing caps should be installed with the part number towards the right side. Caps are to be identified by stamped numbers 1 thru 7 located on the bottom unmachined surface.6. Put main bearing caps (2) in position on the cylinder block. Put engine oil or molylube on the bolt threads and the washer face, then install the bolts. Tighten the bolts on the side where the main bearing tabs are located to a torque of 95 5 N m (70 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 95 5 N m (70 4 lb.ft.).7. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an additional 90° 5° turn. Then turn the bolts on the side where the main bearing tabs are located an additional 90° 5° turn.
Typical Example8. Check the end play of the crankshaft with a dial indicator and magnetic base. The end play must be 0.1 to 0.5 mm (.004 to .020 in.). The end play is controlled by thrust bearings (4), which are located at the center main.End By:a. install underframeb. install oil pan
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and cylinder block. This can cause damage to either or both the crankshaft and block.
3. Remove the upper half of main bearings (3) as follows:a. Turn the crankshaft until tool (A) can be installed in the crankshaft journal. Install tool (A).b. Turn the crankshaft in the direction which will push the upper main bearing out, tab end first.c. Check the condition of the bearings. (See Guideline For Reusable Parts, Main And Connecting Rod Bearings, Form No. SEBF8009 and SEBD0531). The following steps are for the installation of the crankshaft main bearings. Put clean engine oil on the main bearings for the assembly. Also, be sure the tabs on the back side of the main bearings fit in the grooves of the main bearing caps and cylinder block.4. Clean the surfaces in the cylinder block for the main bearings. Use tool (A), and install new upper halves of main bearing (bearings with the oil hole) in the cylinder block. Do not put oil on the back of the bearing.5. Clean the surface of the main bearing caps for the main bearings. Install the new lower halves of the main bearings in the main caps. Do not put oil on the back of the bearing. Main bearing caps should be installed with the part number towards the right side. Caps are to be identified by stamped numbers 1 thru 7 located on the bottom unmachined surface.6. Put main bearing caps (2) in position on the cylinder block. Put engine oil or molylube on the bolt threads and the washer face, then install the bolts. Tighten the bolts on the side where the main bearing tabs are located to a torque of 95 5 N m (70 4 lb.ft.). Tighten the bolts on the opposite side to a torque of 95 5 N m (70 4 lb.ft.).7. Put a mark on each bolt head and the bearing caps. Turn the bolts that are opposite the main bearing tabs an additional 90° 5° turn. Then turn the bolts on the side where the main bearing tabs are located an additional 90° 5° turn.
Typical Example8. Check the end play of the crankshaft with a dial indicator and magnetic base. The end play must be 0.1 to 0.5 mm (.004 to .020 in.). The end play is controlled by thrust bearings (4), which are located at the center main.End By:a. install underframeb. install oil pan
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Group cross 101431-4120 ZEXEL
Isuzu
101431-4120
8943254660
INJECTION-PUMP ASSEMBLY
C240
C240