Information injection-pump assembly
ZEXEL
101491-0041
1014910041
ISUZU
5156011964
5156011964
Rating:
Cross reference number
ZEXEL
101491-0041
1014910041
ISUZU
5156011964
5156011964
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.4
3.35
3.45
Rack position
Point A R=A
Point A R=A
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
-
Rack position
10.4
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
55
53.4
56.6
Max. variation between cylinders
%
0
-2.6
2.6
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
6.7
5.2
8.2
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.4)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
55
54
56
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
10.3+-0.
5
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
54.8
53.2
56.4
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
10.5+-0.
5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
42.5
40.9
44.1
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
11.1+-0.
5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
45.4
43.4
47.4
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
Z
Rack position
10.1+-0.
5
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
48.9
47.3
50.5
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1650--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1600
Advance angle
deg.
0.6
Timer adjustment_03
Pump speed
r/min
1800
Advance angle
deg.
3
2.5
3.5
Timer adjustment_04
Pump speed
r/min
1900
Advance angle
deg.
4.5
4
5
Timer adjustment_05
Pump speed
r/min
-
Advance angle
deg.
5
5
5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Torque control stroke: L1
----------
T1=55 L1=1mm
----------
----------
T1=55 L1=1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=5.5deg+-5deg b=38deg+-3deg
----------
----------
a=5.5deg+-5deg b=38deg+-3deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=15deg
----------
a=(100deg)
----------
aa=15deg
----------
a=(100deg)
Information:
Measure wear of the cylinder bore at the top and bottom of piston ring travel.(1) Cylinder bore [standard, original size] ... 4.5005 .0005 in.(114.313 0.013 mm) The recommendation is made to make the cylinder bore the next size larger when the size of the bore is ... 4.5060 in.(114.452 mm)Cylinder bore must be made the next size larger when the size of the bore is ... 4.5090 in.(114.529 mm)Cylinder bore [.020 in. (0.51 mm) larger than the original size] ... 4.5205 .0005 in.(114.821 0.013 mm)The recommendation is made to make the cylinder bore the next size larger when the size of the bore is ... 4.5260 in.(114.960 mm)Cylinder bore must be made the next size larger when the size of the bore is ... 4.5290 in.(115.037 mm)Cylinder bore [.040 in. (1.02 mm) larger than the original size] ... 4.5405 .0005 in.(115.329 0.013 mm)Maximum permissible wear of cylinder bores (replacement of the cylinder block is necessary) ... 4.5490 in.(115.545 mm)(2) Bore in block for camshaft bearing ... 2.6525 .0005 in.(67.374 0.013 mm)(3) Width of main bearing cap ... 6.5600 .0005 in.(116.624 0.013 mm) Minimum permissible width of main bearing cap ... 6.5580 in.(116.573 mm)Width of main bearing cap guide (in cylinder block) ... 6.5590 .0005 in.(116.599 0.013 mm)(4) Bore in block for main bearing ... 3.7075 .0005 in.(94.171 0.013 mm) Permissible amount of distortion in bore ... 3.706 to 3.709 in.(94.13 to 94.21 mm)(5) Torque for bolts holding caps for main bearings: A. Put crankcase oil on bolt threads and washer face.B. Tighten all bolts by number to ... 60 15 lb. ft.(8.3 2.0 mkg)C. Again tighten all bolts by number to ... 175 10 lb. ft.(24.2 1.4 mkg)Engines with Serial Numbers 98M2494 and Up, tighten bolts (5) holding caps for main bearings in the following sequence: 1. Put crankcase oil on bolt threads and washer face.2. Tighten all bolts by number to ... 30 3 lb. ft.(4.1 0.4 mkg)3. Put a mark on each bolt and cap.4. Tighten all bolts by number from mark ... 120° 5°