Information injection-pump assembly
ZEXEL
101603-2700
1016032700
Rating:
Cross reference number
ZEXEL
101603-2700
1016032700
Zexel num
Bosch num
Firm num
Name
101603-2700
INJECTION-PUMP ASSEMBLY
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
134424-0920
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
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
1-4-2-6-
3-5
Pre-stroke
mm
4.8
4.77
4.83
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
10.6
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
108.5
107
110
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
36
36
Boost pressure
mmHg
270
270
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.2+-0.5
Pump speed
r/min
455
455
455
Average injection quantity
mm3/st.
10
9
11
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
130
130
140
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
9.15
Boost pressure
kPa
5.3
4
6.6
Boost pressure
mmHg
40
30
50
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
10.6
Boost pressure
kPa
22.7
16
29.4
Boost pressure
mmHg
170
120
220
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1000
Remarks
Measure the actual advance angle.
Measure the actual advance angle.
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
1.5
1.2
1.8
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Main spring setting
(5)Set idle sub-spring
(6)Boost compensator stroke: BCL
----------
K=7 BCL=(1.45)mm
----------
----------
K=7 BCL=(1.45)mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=100mm
----------
a=(1deg)+-5deg b=(19deg)+-5deg
----------
aa=100mm
----------
a=(1deg)+-5deg b=(19deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Flangeless Liners
(1) Outside diameter of cylinder liner ... 103.28 to 103.30 mm (4.066 to 4.067 in)(2) Inside diameter of cylinder liner ... 98.48 to 98.50 mm (3.877 to 3.878 in) Maximum diameter wear (when boring or new liners are needed) ... 0.20 mm (0.008 in)Interference fit of liner in cylinder block ... 0.08 to 0.13 mm (0.003 to 0.005 in)Length of cylinder liner ... 228.73 to 228.98 mm (9.005 to 9.015 in)Maximum cylinder liner can be bored (made larger than original size) ... 0.76 mm (0.030 in) The 4.236 flangeless cylinder liners are the only ones that can be bored. All other liners must be replaced when worn beyond specifications.(3) Liner projection (height of liner above face of cylinder block) ... 0.71 to 0.94 mm (0.028 to 0.037 in)(4) Diameter of parent bore in cylinder block for liner ... 103.162 to 103.188 mm (4.0615 to 4.0625 in)Flanged Liners
New cylinder blocks have been introduced on the 4.236 engine. The 4.236 engine has a larger cylinder liner parent bore diameter and the outside diameter of the cylinder liner is also larger. The liners will no longer have a flame ring. Effective with this change only flanged liners will be available. The change became effective at engine serial number LDU106654N and up. See General Information in Systems Operation for the serial number location.(1) Outside diameter of cylinder liner.Earlier engines with thin wall liners: Production liner ... 103.238 to 103.264 mm (4.0645 to 4.0655 in)Service liner ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners: Production liner ... 104.254 to 104.280 mm (4.1045 to 4.1055 in)Service liner ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)(2) Inside diameter of cylinder liner: Production liner ... 98.48 to 98.50 mm (3.877 to 3.878 in)Service liner ... 98.50 to 98.53 mm (3.878 to 3.879 in)Maximum diameter wear (when new liners are needed ... 0.20 mm (0.008 in)Transition fit of service liner in cylinder block ... 0.03 mm ( 0.001 in)Length of cylinder liner with flame ring ... 227.10 to 227.43 mm (8.941 to 8.954 in)Length of cylinder liner without flame ring ... 226.03 to 226.82 mm (8.899 to 8.930 in)(3) Liner (flange) projection [do not measure from flame ring (if equipped)] ... 0.10 mm (0.004 in) above to 0.10 mm (0.004 in) below face of cylinder block. Flange thickness of cylinder liner ... 3.81 to 3.86 mm (0.150 to 0.152 in)(4) Diameter of parent bore in cylinder block in liner: Earlier engines with thin wall liners ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)Depth of recess for cylinder liner flange ... 3.81 to 3.91 mm (0.150 to 0.154 in)All Engine Blocks
(5) Diameter of bore in cylinder block for camshaft No. 1 front bearing [has only front bearing (6)] ...
(1) Outside diameter of cylinder liner ... 103.28 to 103.30 mm (4.066 to 4.067 in)(2) Inside diameter of cylinder liner ... 98.48 to 98.50 mm (3.877 to 3.878 in) Maximum diameter wear (when boring or new liners are needed) ... 0.20 mm (0.008 in)Interference fit of liner in cylinder block ... 0.08 to 0.13 mm (0.003 to 0.005 in)Length of cylinder liner ... 228.73 to 228.98 mm (9.005 to 9.015 in)Maximum cylinder liner can be bored (made larger than original size) ... 0.76 mm (0.030 in) The 4.236 flangeless cylinder liners are the only ones that can be bored. All other liners must be replaced when worn beyond specifications.(3) Liner projection (height of liner above face of cylinder block) ... 0.71 to 0.94 mm (0.028 to 0.037 in)(4) Diameter of parent bore in cylinder block for liner ... 103.162 to 103.188 mm (4.0615 to 4.0625 in)Flanged Liners
New cylinder blocks have been introduced on the 4.236 engine. The 4.236 engine has a larger cylinder liner parent bore diameter and the outside diameter of the cylinder liner is also larger. The liners will no longer have a flame ring. Effective with this change only flanged liners will be available. The change became effective at engine serial number LDU106654N and up. See General Information in Systems Operation for the serial number location.(1) Outside diameter of cylinder liner.Earlier engines with thin wall liners: Production liner ... 103.238 to 103.264 mm (4.0645 to 4.0655 in)Service liner ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners: Production liner ... 104.254 to 104.280 mm (4.1045 to 4.1055 in)Service liner ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)(2) Inside diameter of cylinder liner: Production liner ... 98.48 to 98.50 mm (3.877 to 3.878 in)Service liner ... 98.50 to 98.53 mm (3.878 to 3.879 in)Maximum diameter wear (when new liners are needed ... 0.20 mm (0.008 in)Transition fit of service liner in cylinder block ... 0.03 mm ( 0.001 in)Length of cylinder liner with flame ring ... 227.10 to 227.43 mm (8.941 to 8.954 in)Length of cylinder liner without flame ring ... 226.03 to 226.82 mm (8.899 to 8.930 in)(3) Liner (flange) projection [do not measure from flame ring (if equipped)] ... 0.10 mm (0.004 in) above to 0.10 mm (0.004 in) below face of cylinder block. Flange thickness of cylinder liner ... 3.81 to 3.86 mm (0.150 to 0.152 in)(4) Diameter of parent bore in cylinder block in liner: Earlier engines with thin wall liners ... 103.188 to 103.213 mm (4.0625 to 4.0635 in)Current engines with thick wall liners ... 104.204 to 104.229 mm (4.1025 to 4.1035 in)Depth of recess for cylinder liner flange ... 3.81 to 3.91 mm (0.150 to 0.154 in)All Engine Blocks
(5) Diameter of bore in cylinder block for camshaft No. 1 front bearing [has only front bearing (6)] ...
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101603-2700
INJECTION-PUMP ASSEMBLY