101432-0240 ZEXEL 9 400 610 126 BOSCH INJECTION-PUMP ASSEMBLY 9400610126 1014320240 5156011682


 

Information injection-pump assembly

BOSCH 9 400 610 126 9400610126
ZEXEL 101432-0240 1014320240
ISUZU 5156011682 5156011682
101432-0240 INJECTION-PUMP ASSEMBLY
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Service parts 101432-0240 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101043-9160
3. GOVERNOR 105542-3430
4. SUPPLY PUMP 105220-4742
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156635-6320
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:

101432-0240 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 610 126 9400610126
ZEXEL 101432-0240 1014320240
ISUZU 5156011682 5156011682


Zexel num
Bosch num
Firm num
Name
101432-0240 
9 400 610 126 
5156011682  ISUZU
INJECTION-PUMP ASSEMBLY
C240 K 14BC INJECTION PUMP ASSY 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   12.1
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   34.8 33.2 36.4
Max. variation between cylinders %   0 -4 4
Fixing the rack   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   11.5
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   33.5 32.5 34.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   -
Rack position   7.9+-0.5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   7.2 6.1 8.3
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 

Test data Ex:

Governor adjustment

Test data 101432-0240
N:Pump speed R:Rack position (mm) P:Negative pressure (1)Pneumatic governor (2)Beginning of idle sub spring operation: L1 (3)Mechanical governor (4)Acting negative pressure: P1
----------
L1=7.4+-0.3mm
----------

0000001101

Test data 101432-0240
N:Normal S:Stop B:When boosted (1)Rack position = aa
----------
aa=18mm
----------
a=23deg+-3deg b=15.5deg+-5deg c=2.5deg+-5deg

Timing setting

Test data 101432-0240
(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=18deg
----------
a=(60deg)




Information:


Location of Screwdriver While Holding BellcrankK. Rotate the timing position sensor bellcrank clock wise by inserting the No. 2 Phillips screwdriver between the arm of the bellcrank in contact with the timing position sensor until the screwdriver can be inserted into the hole in the cover to hold the bellcrank in position.
Hold Timing Position Sensor Bellcrank In PositionL. Install the gasket and timing advance housing (4).M. Remove the screwdriver to allow the bellcrank to contact the power piston.9. Check the timing sensor position calibration as described in P-531: Timing Position Sensor/Calibration.10. Install the timing solenoid (BTM). Make sure the arm of the timing solenoid is in the center groove of the control spool collar.11. Install the timing advance position sensor cover (3).P-540: Idle Shutdown Timer
System Operation
The idle shutdown timer is a feature which helps improve fuel consumption by limiting idling time. The timer may be programmed to shut down the idling engine after a period of time. This "shutdown time" is a customer specified parameter, and may be programmed for any period from 3 to 60 minutes. Programming the time to zero disables the idle shutdown timer.The timer is activated when the parking brake is set, vehicle speed is zero, and the engine is not under load. Ninety seconds before the programmed time is reached, the diagnostic lamp will begin to flash rapidly. If the driver moves the clutch pedal or brake pedal during this 90 second period, the timer will be overridden and is reset. A diagnostic code 71-00 will be set when the driver overrides the timer using the clutch or brake.If the timer is activated and allowed to shutdown the engine, then a code 71-01 will be set. Code 71-01 merely records the event and does not indicate a fault in PEEC III. If any of the codes for vehicle speed are Active, the idle shutdown timer will not operate.Diagnostic Codes
Functional Test
P-541: Multi-Torque
System Operation
Multi-Torque is an optional feature available with certain PEEC III engines. The feature is available only in certain personality modules.The 310 Multi-Torque provides an otherwise standard 310 hp PEEC III engine with two different torque curves. In all gears except top gear, the engine performs as a standard 310 hp PEEC III. In top gear, however, the engine is provided with the torque of a standard 310 hp at 1800 rpm, but with the peak torque of 350 hp at 1150 rpm (see the following illustrations).PEEC III determines whether the vehicle is in top gear by sensing the ratio of engine speed to vehicle speed. If the ratio of engine speed/vehicle speed is less than 26.6, the engine will perform like a standard 310 hp PEEC III.The 350 Multi-Torque works just like the 310Multi-Torque, except for two key differences. First, the multi-torque curve provides the engine with the standard 350 hp torque at 1800 rpm, and with the peak torque of a 400 hp at 1200 rpm (see the following illustration). Second, the multi-torque is in effect in the top two gears,

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