101607-6360 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016076360


 

Information injection-pump assembly

ZEXEL 101607-6360 1016076360
101607-6360 INJECTION-PUMP ASSEMBLY
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Service parts 101607-6360 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-9690
3. GOVERNOR 105931-9760
4. SUPPLY PUMP 105210-4700
5. AUTOM. ADVANCE MECHANIS 105643-0180
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6780
11. Nozzle and Holder ME076000
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105031-3900
14. NOZZLE 105015-6440
15. NOZZLE SET

Include in #1:

101607-6360 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101607-6360 1016076360


Zexel num
Bosch num
Firm num
Name
101607-6360 
 
   
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   131424-5520
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.3 3.25 3.35
Beginning of injection position
Governor 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   -
Rack position   11.4
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   54.5 52.9 56.1
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   D
Rack position   8.7+-0.5
Pump speed r/min   500 500 500
Each cylinder's injection qty mm3/st.   7.6 6.5 8.7
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.4)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   54.5 53.5 55.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.4
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   79.8 75.8 83.8
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1(11.4)
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   48.5 44.5 52.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   14.3+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   73 63 83
Fixing the lever   *
Rack limit   *
Injection quantity adjustment_07
Adjusting point   H
Rack position   9.5+-0.5
Pump speed r/min   275 275 275
Each cylinder's injection qty mm3/st.   8.7 7.4 10
Fixing the rack   *
Remarks
(check)
 
Timer adjustment
Pump speed r/min   900--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   850
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1200
Advance angle deg.   2.7 2.2 3.2
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101607-6360
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=D53
----------

Speed control lever angle

Test data 101607-6360
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=41deg+-3deg

Stop lever angle

Test data 101607-6360
N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee (speed lever full, speed = ff). (4)Free (at delivery)
----------
aa=1450r/min bb=4.7-0.5mm cc=275r/min dd=(6.3)mm ee=15mm ff=0r/min
----------
a=38.5deg+-5deg b=(29deg) c=17deg+-5deg

0000001501 LEVER

Test data 101607-6360
(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=41deg+-3deg c=18.5deg+-5deg

Timing setting

Test data 101607-6360
(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(1deg)




Information:


Oils that have more than 1% total sulfated ash should not be used in aftertreatment device equipped engines.In order to achieve expected ash service intervals, performance, and life, aftertreatment device equipped diesel engines require the use of Cat DEO-ULS or oils meeting the Cat ECF-3 specification and the API CJ-4 oil category. Use of oils with more than 1% total sulfated ash in aftertreatment device equipped engines will cause the need for more frequent ash service intervals, and/or cause loss of performance. Refer to your engine specific Operation and Maintenance Manual, and refer to your aftertreatment device documentation for additional guidance.
API category oils that have not met the requirements of at least one Cat ECF specification may cause reduced engine life.
In selecting oil for any engine application, both the oil viscosity and oil performance category/specification as specified by the engine manufacturer must be defined and satisfied. Using only one of these parameters will not sufficiently define oil for an engine application.
In order to make the proper diesel engine oil viscosity grade choice, refer to the applicable “Lubricant Viscosities for Ambient Temperatures” table in this Special Publication.
Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.
Total Base Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines
The minimum required Total Base Number (TBN) for oil depends on the fuel sulfur level. The TBN for new oil is typically determined by the "ASTM D2896" procedure. For direct injection engines that use distillate fuel, the following guidelines apply.
Table 3
TBN recommendations for applications in Cat engines
Fuel Sulfur Level percent (ppm) Cat Engine Oils TBN of Commercial Engine Oils
≤0.05 percent (≤500 ppm) Cat DEO-ULS, Cat DEO Min 7
0. 1 - 0.05 percent (1000-500 ppm) Cat DEO-ULS, Cat DEO Min 7
Above 0.1 percent (above 1000 ppm) Cat DEO Min 10 Reaching one half of new oil TBN is one of the condemning factors for diesel engine oil. In order to help provide the best protection for your engine, Cat S O S Services oil analysis is the preferred method for determining oil life. TBN of the oil is typically measured using "ASTM D2896" and/or the "ASTM D4739" test methods. It is recommended to change the oil when one half of new oil TBN with either method is reached.For example, new oil with a TBN of 10 by "ASTM D2896" should be changed when, during use, the TBN deteriorates to 5 as determined by the "ASTM D2896" test method. New oil with a TBN of 10 by "ASTM D4739" should be changed when, during use, the TBN deteriorates to 5 as determined by the "ASTM D4739" test method.Note: TBN is also commonly referred to as Base Number (BN).Excessive piston deposits can be produced by oil with a high TBN and/or high ash. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore.The use of Cat S O S Services oil analysis helps the environmental

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