Information injection-pump assembly
ZEXEL
101601-4392
1016014392
ISUZU
5156008805
5156008805
Rating:
Service parts 101601-4392 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-089-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-4392
1016014392
ISUZU
5156008805
5156008805
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 opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
60
58.4
61.6
Max. variation between cylinders
%
0
-2.5
2.5
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
325
325
325
Average injection quantity
mm3/st.
9.3
8
10.6
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(11.6)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
60
59
61
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.15
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
66.5
62.5
70.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1(11.6)
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
62.1
58.9
65.3
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.1
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
47.5
44.3
50.7
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1000
Advance angle
deg.
0.3
Timer adjustment_02
Pump speed
r/min
1050
Advance angle
deg.
0.7
Timer adjustment_03
Pump speed
r/min
1300
Advance angle
deg.
1.8
1.3
2.3
Timer adjustment_04
Pump speed
r/min
1600
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT: RAL
----------
T1=D99 RAL=(14.5)+0.2mm
----------
----------
T1=D99 RAL=(14.5)+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=39deg+-5deg b=40deg+-3deg
----------
----------
a=39deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(20deg)
----------
----------
a=(20deg)
Information:
Remove Rocker Shaft Assemblies And Push Rods
START BY:a. remove valve covers 1. Remove four bolts (1) from the turbocharger tube adapter to the aftercooler housing. Loosen the turbocharger compressor housing clamp, and rotate turbocharger tube (2) out of the way of the cylinder head assembly. 2. Remove bolts (3) that hold the valve cover bases to the cylinder head assembly. Remove valve cover bases (4).
To prevent damage to the fuel injection nozzle, hold adapter assembly (5) in position at the top of injection nozzle (6) when fuel line nut (7) is loosened or tightened.
3. Use tool (A) and a 5P328 crowfoot wrench (7/8") to loosen the fuel injection line nut at the nozzle end. 4. Use tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (8). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 5. Remove bolts (9) that hold the rocker shaft assemblies to the cylinder head assembly.6. Remove rocker shaft assemblies (10). 7. Put identification marks on the push rods as to their location in the engine. Remove push rods (11). 8. Put identification marks on the bridges as to their location in the engine. Remove bridges (12) from the dowels on the cylinder head assembly.Install Rocker Shaft Assemblies And Push Rods
1. Put clean engine oil on the bridges and dowels. Install the original bridges in their respective locations. New bridges can be mixed.2. Install bridges (1) on the bridge dowels. While firmly pressing 0.5 to 4.5 kg (1 to 10 lb.) straight down on the top contact surface of the bridge, turn the adjusting screw clockwise until contact is made with the valve stem. Turn the screw an additional 20° to 30° (1/3 to 1/2 of 1 hex on nut). This will straighten the dowel in the guide and compensate for the slack in the threads. Hold the adjusting screw in this position, and tighten the locknut to a torque of 30 4 N m (22 3 lb.ft.). Install original push rods in their respective locations in the engine. New push rods can be mixed.3. Install push rods (2). 4. Put rocker shaft assemblies (3) in position on the cylinder head assembly.5. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the rocker shaft assemblies in place. Tighten the bolts first to a torque of 270 25 N m (200 18 lb.ft.). Start with the bolt in the center of the rocker shaft assembly. Tighten the bolts again to a torque of 450 20 N m (330 15 lb.ft.). Tighten the bolts again by hand to a torque of 450 20 N m (330 15 lb.ft.).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (4). Tighten the fuel injection line adapter nuts (5) to a torque of 40 7 N m (30 5 lb.ft.)
START BY:a. remove valve covers 1. Remove four bolts (1) from the turbocharger tube adapter to the aftercooler housing. Loosen the turbocharger compressor housing clamp, and rotate turbocharger tube (2) out of the way of the cylinder head assembly. 2. Remove bolts (3) that hold the valve cover bases to the cylinder head assembly. Remove valve cover bases (4).
To prevent damage to the fuel injection nozzle, hold adapter assembly (5) in position at the top of injection nozzle (6) when fuel line nut (7) is loosened or tightened.
3. Use tool (A) and a 5P328 crowfoot wrench (7/8") to loosen the fuel injection line nut at the nozzle end. 4. Use tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (8). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 5. Remove bolts (9) that hold the rocker shaft assemblies to the cylinder head assembly.6. Remove rocker shaft assemblies (10). 7. Put identification marks on the push rods as to their location in the engine. Remove push rods (11). 8. Put identification marks on the bridges as to their location in the engine. Remove bridges (12) from the dowels on the cylinder head assembly.Install Rocker Shaft Assemblies And Push Rods
1. Put clean engine oil on the bridges and dowels. Install the original bridges in their respective locations. New bridges can be mixed.2. Install bridges (1) on the bridge dowels. While firmly pressing 0.5 to 4.5 kg (1 to 10 lb.) straight down on the top contact surface of the bridge, turn the adjusting screw clockwise until contact is made with the valve stem. Turn the screw an additional 20° to 30° (1/3 to 1/2 of 1 hex on nut). This will straighten the dowel in the guide and compensate for the slack in the threads. Hold the adjusting screw in this position, and tighten the locknut to a torque of 30 4 N m (22 3 lb.ft.). Install original push rods in their respective locations in the engine. New push rods can be mixed.3. Install push rods (2). 4. Put rocker shaft assemblies (3) in position on the cylinder head assembly.5. Put 5P3931 Anti-Seize Compound on the threads of the bolts that hold the rocker shaft assemblies in place. Tighten the bolts first to a torque of 270 25 N m (200 18 lb.ft.). Start with the bolt in the center of the rocker shaft assembly. Tighten the bolts again to a torque of 450 20 N m (330 15 lb.ft.). Tighten the bolts again by hand to a torque of 450 20 N m (330 15 lb.ft.).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (4). Tighten the fuel injection line adapter nuts (5) to a torque of 40 7 N m (30 5 lb.ft.)