Information injection-pump assembly
ZEXEL
101492-0400
1014920400
ISUZU
8943627520
8943627520
Rating:
Service parts 101492-0400 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-94451-183-3
12.
Open Pre:MPa(Kqf/cm2)
19.6(200)
15.
NOZZLE SET
Cross reference number
ZEXEL
101492-0400
1014920400
ISUZU
8943627520
8943627520
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
Overflow valve
131424-0820
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
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
3.3
3.25
3.35
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
10.6
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
83.2
82.2
84.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.6+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
8
6
10
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)The torque control spring does not operate.
(3)Set idle sub-spring
(4)Main spring setting
(5)Rack difference from N = N1
----------
K=12 N1=1550r/min
----------
----------
K=12 N1=1550r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=31deg+-5deg b=122deg+-5deg
----------
----------
a=31deg+-5deg b=122deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=2.5deg+-5deg b=53deg+-5deg
----------
----------
a=2.5deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'V' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18deg
----------
a=(200deg)
----------
aa=18deg
----------
a=(200deg)
Information:
Piston Group.(1) Crater. The piston is a symmetrical piston with an "on center" crater. Thoroughly lubricate piston group 360° in zone (A) with clean engine oil prior to inserting into the block group.(2) Top piston ring. Install ring with side marked "UP-1" toward top of piston (yellow color stripe to right of ring end gap).Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 125.000 mm (4.9213 in) ... 0.625 0.125 mm (.0250 .0050 in)Increase in clearance between ends of piston ring for each 0.03 mm (.001 in) increase in cylinder liner bore size ... 0.09 mm (.004 in)(3) Intermediate piston ring. Install ring with side marked "UP-2" toward top of piston (green color stripe to right of ring end gap).Width of groove in piston for intermediate ring (new) ... 3.061 0.013 mm (.1032 .0005 in)Depth of groove in piston for intermediate ring (new) ... 3.727 mm (.1467 in)Thickness of intermediate ring (new) ... 2.990 0.010 mm (.1177 .0004 in)Clearance between groove and intermediate ring (new) ... 0.048 to 0.094 mm (.0002 to .0037 in)Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 125.000 mm (4.9213 in) ... 0.625 0.125 mm (.0250 .0050 in)Increase in clearance between ends of piston ring for each 0.03 mm (.001 in) increase in cylinder liner bore size ... 0.09 mm (.004 in)(4) Oil regulating piston ring. Oil ring spring ends to be assembled 180° from ring end gap (white colored portion of spring must be visible at ring end gap).Width of groove in piston for oil ring (new) ... 4.033 0.013 mm (.1588 .0005 in)Depth of groove in piston for oil ring (new) ... 3.727 mm (.1467 in)Thickness of oil ring (new) ... 3.987 0.013 mm (.1570 .0005 in)Clearance between groove and oil ring (new) ... 0.020 to 0.072 mm (.0008 to .0028 in)Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 125.000 mm (4.9213 in) ... 0.55 0.15 mm (.022 .006 in)Increase in clearance between ends of piston ring for each 0.03 mm (.001 in) increase in cylinder liner bore size ... 0.09 mm (.004 in)After piston rings have been installed, rotate rings so the end gaps are 120° apart.(5) Crown assembly.(6) Piston pin bore diameter in piston skirt ... 51.15 0.15 mm (2.014 .006 in)Thoroughly lubricate piston pin with clean engine oil prior to inserting into piston group and rod assembly.(7) Piston skirt.