Information injection-pump assembly
ZEXEL
101431-0590
1014310590
ISUZU
5156010252
5156010252
Rating:
Service parts 101431-0590 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-039-1
12.
Open Pre:MPa(Kqf/cm2)
11.8{120}
15.
NOZZLE SET
Cross reference number
ZEXEL
101431-0590
1014310590
ISUZU
5156010252
5156010252
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)
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
2.25
2.2
2.3
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
10.7
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
30
28.6
31.4
Max. variation between cylinders
%
0
-4.5
4.5
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
12.4
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
40.4
39.4
41.4
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
6.8
5.7
7.9
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Timer adjustment
Pump speed
r/min
500+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
1.3
0.6
2
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
6
6
6
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Control lever's minimum speed setting
(3)Idle sub spring setting: L1.
----------
K=5 L1=6.2mm
----------
----------
K=5 L1=6.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=4deg+-5deg b=25deg+-5deg
----------
----------
a=4deg+-5deg b=25deg+-5deg
Timing setting
(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=14deg
----------
a=(60deg)
----------
aa=14deg
----------
a=(60deg)
Information:
Make reference to Guideline For Reusable Parts; Pistons, Form No. SEBF8049; Cylinder Liners, Form No. SEBF8068; and Piston Pins And Retaining Rings, Form No. SEBF8051. For installation, number on tab groove side of connecting rod is to be positioned toward opposite side of engine from camshaft.Top And Intermediate Ring
The 8T3150 Keystone Piston Ring Groove Gauge is necessary for measuring ring groove in keystone style pistons. For correct use of the gauge group, see the instruction card that is with the gauge group.Install piston rings with "UP" side toward top of piston.(1) Top Ring has the mark "UP-1."(2) Intermediate ring has the mark "UP-2".Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 137.16 mm (5.400 in)Top ring ... 0.724 0.191 mm (.0285 .0075 in)Intermediate ring ... 1.080 0.190 mm (.0425 .0075 in)Increase in clearance between ends of piston rings for each 0.03 mm (.001 in) increase in cylinder liner bore size ... 0.08 mm (.003 in)Oil Control Ring
(3) Install oil control ring with the gap in the spring 180° away from the gap in the ring. White portion of spring must be visible at the ring end gap.Width of groove in piston for piston ring (new) ... 3.210 0.010 mm (.1264 .0004 in)Thickness of piston ring (new) ... 3.137 0.013 mm (.1235 .0005 in)Clearance between groove and piston ring (new) ... 0.073 0.023 mm (.0029 .0009 in)Maximum permissible clearance (worn) ... 0.15 mm (.006 in)Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 137.16 mm (5.400 in) ... 0.572 0.191 mm (.0225 .0075 in)Increase in clearance between ends of piston ring for each 0.03 mm (.001 in) increase in cylinder liner bore size ... 0.08 mm (.003 in)Piston Pin Bore
(4) Bore in piston for pin. 1991 Model with elliptical pin bore (310 - 425 hp) Vertical ... 50.814 0.004 mm (2.0005 .0001 in)Horizontal ... actual vertical diameter plus 0.032 to 0.048 mm (.0012 to .0019 in)Clearance between pin and bore in piston ... 0.010 to 0.028 mm (.0004 to .0011 in)Permissible clearance (worn) ... 0.05 mm (.002 in)Pin diameter ... 50.795 0.005 mm (1.9998 .0002 in) Low Crevice Volume and Gallery Pistons Bore in piston for pin ... 50.814 0.004 mm (2.0005 .0001 in)Clearance between pin and bore in piston ... 0.010 to 0.028 mm (.0004 to .0011 in)Permissible clearance (worn) ... 0.05 mm (.002 in)Pin diameter ... 50.795 0.005 mm (1.9998 .0002 in)All Other Pistons Bore in piston for pin ... 50.815 0.008 mm (2.0006 .0003 in)Clearance between pin and bore in piston ... 0.007 to 0.032 mm (.0003 to .0013 in)Permissible clearance (worn) ... 0.05 mm (.002 in)Pin diameter ... 50.795 0.005 mm (1.9998 .0002 in)
The 8T3150 Keystone Piston Ring Groove Gauge is necessary for measuring ring groove in keystone style pistons. For correct use of the gauge group, see the instruction card that is with the gauge group.Install piston rings with "UP" side toward top of piston.(1) Top Ring has the mark "UP-1."(2) Intermediate ring has the mark "UP-2".Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 137.16 mm (5.400 in)Top ring ... 0.724 0.191 mm (.0285 .0075 in)Intermediate ring ... 1.080 0.190 mm (.0425 .0075 in)Increase in clearance between ends of piston rings for each 0.03 mm (.001 in) increase in cylinder liner bore size ... 0.08 mm (.003 in)Oil Control Ring
(3) Install oil control ring with the gap in the spring 180° away from the gap in the ring. White portion of spring must be visible at the ring end gap.Width of groove in piston for piston ring (new) ... 3.210 0.010 mm (.1264 .0004 in)Thickness of piston ring (new) ... 3.137 0.013 mm (.1235 .0005 in)Clearance between groove and piston ring (new) ... 0.073 0.023 mm (.0029 .0009 in)Maximum permissible clearance (worn) ... 0.15 mm (.006 in)Clearance between ends of piston ring when installed in a cylinder liner with a bore size of 137.16 mm (5.400 in) ... 0.572 0.191 mm (.0225 .0075 in)Increase in clearance between ends of piston ring for each 0.03 mm (.001 in) increase in cylinder liner bore size ... 0.08 mm (.003 in)Piston Pin Bore
(4) Bore in piston for pin. 1991 Model with elliptical pin bore (310 - 425 hp) Vertical ... 50.814 0.004 mm (2.0005 .0001 in)Horizontal ... actual vertical diameter plus 0.032 to 0.048 mm (.0012 to .0019 in)Clearance between pin and bore in piston ... 0.010 to 0.028 mm (.0004 to .0011 in)Permissible clearance (worn) ... 0.05 mm (.002 in)Pin diameter ... 50.795 0.005 mm (1.9998 .0002 in) Low Crevice Volume and Gallery Pistons Bore in piston for pin ... 50.814 0.004 mm (2.0005 .0001 in)Clearance between pin and bore in piston ... 0.010 to 0.028 mm (.0004 to .0011 in)Permissible clearance (worn) ... 0.05 mm (.002 in)Pin diameter ... 50.795 0.005 mm (1.9998 .0002 in)All Other Pistons Bore in piston for pin ... 50.815 0.008 mm (2.0006 .0003 in)Clearance between pin and bore in piston ... 0.007 to 0.032 mm (.0003 to .0013 in)Permissible clearance (worn) ... 0.05 mm (.002 in)Pin diameter ... 50.795 0.005 mm (1.9998 .0002 in)