101242-0110 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1012420110 5156005252

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101242-0110 1012420110

ISUZU 5156005252 5156005252

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Service parts 101242-0110 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101024-8000

3. GOVERNOR 105410-1380

4. SUPPLY PUMP 105220-4742

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156635-0620

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:

101242-0110 as INJECTION-PUMP ASSEMBLY

108622-3050 as _

Cross reference number

ZEXEL 101242-0110 1012420110

ISUZU 5156005252 5156005252

Zexel num

Bosch num

Firm num

Name

101242-0110

5156005252 ISUZU

INJECTION-PUMP ASSEMBLY
2AB1 * K 14BA PE1A,2A,3A PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle 105000-1080

Bosch type code DN0SD211

Nozzle holder 105081-3030

Opening pressure MPa 11.8

Opening pressure kgf/cm2 120

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 132424-0620

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-2

Pre-stroke mm 1.95 1.9 2

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 12

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 42 41.2 42.8

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 8+-0.5

Pump speed r/min 475 475 475

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of idle sub spring operation: L1
----------
L1=7.8-0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Pump speed = bb (3)Pump speed cc
----------
aa=900r/min bb=750r/min cc=475r/min
----------
a=3.5deg+-5deg b=3.5deg+-5deg c=19.5deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Z' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(130deg)

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The following changes are adaptable to machines within the listed serial numbers and are effective with all machines after the listed serial numbers.
Illustration 1 g06325715
View of Air lines group on 966M, 972M, 966M XE, and 972M XE machines
(1) 415-8220 Hose
(2) 8T-6703 Hose Clamp
(3) 211-8073 Protection Cap
Illustration 2 g06325708
View of Air lines group on 980M and 982M machines
(1) 365-0045 Hose
(2) 8T-6703 Hose Clamp
(3) 211-8073 Protection Cap
Table 1
Required Parts
Item Qty New Part Number Part Name Former Part Number
1 1 415-8220 (1) Hose 415-8220
365-0045 (2) 365-0045
2 2 8T-6703 Hose Clamp (3) 296-5807
3 2 211-8073 Protection Cap 7X-1443
(1) For 966M, 972M, 966M XE, and 972M XE machines
(2) For 980M and 982M machines
(3) Torque for the hose clamps is 11 2 N m (97 18 lb in).If the CRS hose is found damaged on the above listed machines, replace the hose with same part number. Use hose clamp (2) and protection cap (3) to secure the new hose.The new hose clamp (2) replaces the existing 296-5807 Clamp. The new protection cap (3) replaces the existing 7X-1443 Protector on machines listed above.Torque the hose clamps (2) to 11 2 N m (97 18 lb in).