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101609-3282 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016093282


 

Information injection-pump assembly

ZEXEL 101609-3282 1016093282
101609-3282 INJECTION-PUMP ASSEMBLY
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Service parts 101609-3282 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-9990
3. GOVERNOR 105404-5120
4. SUPPLY PUMP 105220-5960
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER
14. NOZZLE
15. NOZZLE SET

Include in #1:

101609-3282 as INJECTION-PUMP ASSEMBLY

Include in #2:

104257-1030 as _

Cross reference number

ZEXEL 101609-3282 1016093282


Zexel num
Bosch num
Firm num
Name
101609-3282 
 
   
INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions
Test oil
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
Overflow valve   131424-3420
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right   R
Injection order   1-5-3-6- 2-4
Pre-stroke mm   2.5 2.45 2.55
Beginning of injection position
Drive side   NO.1
Difference between angles 1
Cal 1-5 deg.   60 59.5 60.5
Difference between angles 2
Cal 1-3 deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6 deg.   180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg.   240 239.5 240.5
Difference between angles 5
Cal 1-4 deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   A
Rack position   9.7
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   92 91 93
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   7+-0.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   13 12 14
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   70 70 80
Fixing the lever   *
Rack limit   *

Test data Ex:

Governor adjustment

Test data 101609-3282
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Adjust the secondary timing before adjusting the governor. (4)RACK LIMIT (5)Rack difference between N = N1 and N = N2
----------
K=16 N1=1000r/min N2=675r/min
----------

Speed control lever angle

Test data 101609-3282
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=15deg+-3deg b=26deg+-5deg

Stop lever angle

Test data 101609-3282
N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

Test data 101609-3282
(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=17deg bb=0deg
----------
a=54deg54min+-3deg b=8deg30min+-30min




Information:


Cylinder Heads Without Guides
Cylinder Heads With Guides New cylinder heads have been introduced on the 4.236 engine. The new heads have replaceable valve guides. The differences between the earlier and current heads are explained below. The change became effective at engine serial number LD70178U040236M and up. The engine serial number is located above the fuel injection pump on the block.(1) Outer spring: Length under test force ... 27.4 mm (1.08 in)Test force ... 180 9 N (40 2 lb)Free length after test ... 45.2 mm (1.78 in)(Damper coils of spring go toward cylinder head).(2) Inner spring: Length under test force ... 23.88 mm (.940 in)Test force ... 69 9 N (15.4 2 lb)Free length after test ... 39.6 mm (1.56 in)(Damper coils of spring go toward cylinder head).Earlier Cylinder Heads Without Removable Guides
(3) Exhaust valve stem diameter ... 9.449 to 9.469 mm (.372 to .3728 in) Valves are available in stem oversizes of 0.08, 0.38 and 0.76 mm (.003, .015 and .030 in).Exhaust valve overall length ... 123.11 to 123.52 mm (4.847 to 4.863 in)Bore in cylinder head for valve ... 9.506 to 9.531 mm (.37425 to .37525 in)Clearance between valve stem and bore ... 0.0368 to 0.0826 mm (.00145 to .00325 in)Maximum permissible clearance between valve stem and bore ... 0.15 mm (.006 in)(4) Intake valve stem diameter ... 9.462 to 9.487 mm (.3725 to .3735 in) Valves are available in stem oversizes of 0.08, 0.38 and 0.76 mm (.003, .015 and .030 in).Intake valve overall length ... 122.71 to 123.11 mm (4.831 to 4.847 in)Bore in cylinder head for valve ... 9.506 to 9.531 mm (.37425 to .37525 in)Clearance between valve stem and bore ... 0.0191 to 0.0699 mm (.00075 to .00275 in)Maximum permissible clearance between valve stem and bore ... 0.13 mm (.005 in)Current Cylinder Heads With Removable Guides
(5) Valve guides: Inside diameter ... 9.507 to 9.543 mm (.3743 to .3757 in)Outside diameter ... 15.921 to 15.933 mm (.6268 to .6273 in)Parent bore diameter in cylinder head for valve guide ... 15.867 to 15.893 mm (.6247 to .6257 in)Interference fit of guide in cylinder head ... 0.028 to 0.066 mm (.0011 to .0026 in)Overall length of guide:Intake ... 57.94 mm (2.281 in)Exhaust ... 61.11 mm (2.406 in)Projection of guide above valve spring recess ... 15.09 mm (.594 in)(6) Exhaust valve stem diameter ... 9.449 to 9.468 mm (.372 to .3728 in) Clearance of valve in guide ... 0.058 to 0.119 mm (.0023 to .0047 in)Maximum permissible clearance of valve in guide ... 0.13 mm (.005 in)Exhaust valve overall length ... 123.11 to 123.52 mm (4.847 to 4.863 in)(7) Intake valve stem diameter ... 9.462 to 9.487 mm (.3725 to .3735 in) Clearance of valve in guide ... 0.058 to 0.119 mm (.0023 to .0047 in)Maximum permissible clearance of valve in guide ... 0.13 mm (.006 in)Intake valve overall length ... 122.71 to 123.11 mm (4.831 to 4.847 in)All Cylinder Heads
(8) Exhaust valve

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Group cross 101609-3282 ZEXEL

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INJECTION-PUMP ASSEMBLY
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INJECTION-PUMP ASSEMBLY
101609-3282  
 
 
INJECTION-PUMP ASSEMBLY

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101609-3283  
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101609-3283  
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