101608-1351 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081351

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-1351 1016081351

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Service parts 101608-1351 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8760

3. GOVERNOR 105411-1731

4. SUPPLY PUMP 105210-5450

5. AUTOM. ADVANCE MECHANIS 105672-9010

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:

101606-0130 as _

101608-1351 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101608-1351 1016081351

Zexel num

Bosch num

Firm num

Name

101608-1351

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 C

Rack position 8+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8 6.5 9.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Load 4/4

Remarks
Beginning of advance.

Timer adjustment_02

Pump speed r/min 450

Advance angle deg. 2 1.5 2.5

Load 0/4

Remarks
Start

Timer adjustment_03

Pump speed r/min (550)

Advance angle deg. 0 0 0

Load 0/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 0.5

Load 4/4

Timer adjustment_05

Pump speed r/min 1400

Advance angle deg. 2.5 2 3

Load 4/4

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

Speed control lever angle

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

----------
a=(30deg)+-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:

Table 1
Revision Summary of Changes
01 Updated the effectivity. A new Diesel Exhaust Fluid (DEF) filter is now available on machines listed above. The DEF filter has an improved filter efficiency.
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 now available for the products within the listed serial numbers.Refer to Table 2 for a list of a new and former part numbers.
Table 2
Required Parts
DEF Filter DEF Manifold Group
Application New Part Number Part Name Former Part Number (1) New Part Number Part Name Former Part Number (1)
785G 584-8139 DEF Filter 453-1607 585-3956 DEF Manifold Gp 480-4090
789G, 793F, 794AC, 797F, and 994K 584-8140 DEF Filter 453-1608 585-3957 DEF Manifold Gp 480-4091
(1) The former part number listed is for reference only and may differ.Note: The new DEF manifold group part numbers listed in Table 2 will be assembled with the new filters.
Illustration 1 g06570567
DEF manifold
(1) ClampAn additional change, beyond the new DEF filter, was made to the 585-3957 DEF Manifold Gp. The clamp in the location highlighted in Illustration 2 was removed to eliminate a potential wear point.
Illustration 2 g06570636
Typical view of the DEF manifold group
(2) DEF manifold
(3) DEF filterThis change is effective for the Pump Electronic Tank Unit (PETU) serial numbers listed in Table 3.
Table 3
Pump Electronic Tank Unit (PETU) Serial Numbers
S/N:PET001414J
S/N:PET001444J-UP