101608-1030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081030

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-1030 1016081030

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Service parts 101608-1030 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8760

3. GOVERNOR 105411-1730

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105643-1080

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4190

11. Nozzle and Holder ME078067

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105030-3350

14. NOZZLE 105025-0370

15. NOZZLE SET

Include in #1:

101608-1030 as INJECTION-PUMP ASSEMBLY

Include in #2:

104139-1030 as _

Cross reference number

ZEXEL 101608-1030 1016081030

Zexel num

Bosch num

Firm num

Name

101608-1030

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 4.5 4.45 4.55

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 A

Rack position 10.6

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 106 105 107

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

Injection quantity adjustment_02

Adjusting point -

Rack position 8.3+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10 8.5 11.5

Max. variation between cylinders % 0 -15 15

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.

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-0.9

Boost pressure kPa 20 17.3 22.7

Boost pressure mmHg 150 130 170

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(10.6)

Boost pressure kPa 30.7 24 37.4

Boost pressure mmHg 230 180 280

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 2.5 2 3

Remarks
Finish

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)Boost compensator stroke: BCL (4)Main spring setting (5)Set idle sub-spring
----------
K=13 BCL=0.9+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(29deg)+-5deg b=(20deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

Timing setting

(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=10deg
----------
a=(1deg)

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).