101608-1230 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081230

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-1230 1016081230

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Service parts 101608-1230 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8760

3. GOVERNOR 105412-2320

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105643-1130

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:

101608-1230 as INJECTION-PUMP ASSEMBLY

Include in #2:

109341-1042 as _

Cross reference number

ZEXEL 101608-1230 1016081230

Zexel num

Bosch num

Firm num

Name

101608-1230

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 10.8

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 108.5 107.5 109.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.3+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10.5 9 12

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Torque spring does not operate. (4)Main spring setting (5)Set at delivery (6)Set idle sub-spring
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)At delivery (3)Set the pump speed at aa (4)Set the pump speed at bb.
----------
aa=1450r/min bb=1010r/min
----------
a=(28deg)+-5deg b=(1deg) c=(16deg)+-5deg d=(12deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At delivery
----------

----------
a=26deg+-5deg b=53deg+-5deg

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=13deg
----------
a=(0deg)

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.
Table 1
Required Parts
Item Qty Part Number Part Name Former Part Number(1)
1 1 307-3245 Injector As 5T-5045
(1) The former part number listed is for reference only and may differ.
Illustration 1 g06487273
(1) 307-3245 Injector As
Illustration 2 g06487280
(1) 307-3245 Injector AsNew injector assembly (1) is adaptable to the products within the listed serial numbers and is effective with all products after the listed serial numbers.
New injector assembly (1) replaces the former 5T-5045 Lubrication Injector Gp in the 5T-5009 Lubrication Distribution Valve Gp and 8W-2597 Lubrication Distribution Valve Gp.
The former 5T-5009 Lubrication Distribution Valve Gp was replaced by 269-5348 Lubrication Distribution Valve Gp in the 542-2534 Automatic Lubrication Gp, 480-9286 Lubrication Lines Gp, and 461-6749 Automatic Lubrication Gp.
The former 8W-2597 Lubrication Distribution Valve Gp was replaced by 269-5352 Lubrication Distribution Valve Gp in the 480-9286 Lubrication Lines Gp.Note: The 442-3289 Lubrication Valve and Lines Gp is equipped with the 8W-2597 Lubrication Distribution Valve Gp.Note: The 442-3289 Lubrication Valve and Lines Gp was superseded by 449-2424 Fuel Filter.Note: The 499-2424 Lubrication Valve and Lines Gp is equipped with the 5T-5009 Lubrication Distribution Valve Gp.Note: The 499-2424 Lubrication Valve and Lines Gp was superseded by the 542-2354 Lubrication Valve and Lines Gp.