101608-1460 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081460

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-1460 1016081460

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Service parts 101608-1460 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8851

3. GOVERNOR 105932-2001

4. SUPPLY PUMP 105210-6020

5. AUTOM. ADVANCE MECHANIS 105672-5390

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7460

11. Nozzle and Holder ME075788

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-3030

14. NOZZLE

15. NOZZLE SET 105019-0361

Include in #1:

101608-1460 as INJECTION-PUMP ASSEMBLY

107692-1603 as _

Cross reference number

ZEXEL 101608-1460 1016081460

Zexel num

Bosch num

Firm num

Name

101608-1460

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 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 18

Opening pressure kgf/cm2 184

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-8420

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.2 3.15 3.25

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 11.7

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 93.5 90.7 96.3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 310 310 310

Each cylinder's injection qty mm3/st. 10.8 9.2 12.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.7)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 93.5 92.5 94.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.3

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 90 86 94

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.35

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 92.5 88.5 96.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 155 175

Fixing the lever *

Rack limit *

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 1450

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=L97
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=18.5deg+-5deg b=(39deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt so that speed = aa and rack position = bb and 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=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm ff=0r/min
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

0000001601 LEVER

(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=(39deg)+-3deg c=18.5deg+-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=12deg
----------
a=(1deg)

Information:

Illustration 9 g06286243
Typical example
Illustration 9 shows the governor plate displaying high wear at the sleeve contact points.
Illustration 10 g06286261
Typical example
Illustration 8 shows the thrust sleeve displaying an excessive wear groove.
Illustration 11 g06286627
Typical example
Illustration 12 g06286629
Typical example
Illustration 11 and Illustration 11 show the weight thrust fingers badly worn.
Illustration 13 g06286630
Typical example
Illustration 13 shows pivot heels showing excessive wear.Fuel Quality
Illustration 14 g06286604
Typical example
Illustration 14 shows that nitrile rubber seals have cracked causing fuel leakage. The cracks in the seals are attributed to fuel attacking the rubber. Ensure that there is no particle contamination in the fuel injection pump.Unmodified Vegetable Oil or Poor Quality FAME
Illustration 15 g06286612
Typical example
Stuck metering valve causing engine overspeed. Top cover of fuel injection pump removed. Black sticky material adhering to all non-alloy surfaces, this is due to the use of unmodified vegetable oil or poor quality FAME. Refer to Illustration 15.High Water Content in Fuel
Illustration 16 g06286613
Typical example
Illustration 17 g06286615
Typical example
Illustration 16 and Illustration 17 show corrosion on component surfaces, due to high water content in fuel.Characteristics Associated with Poor Quality Fuel and Potential Issue
Table 1
Fuel Characteristics Effect Issue
FAMEs in general Causes some elastomers to soften, swell, harden, and crack. Fuel leakage.
Free methanol in FAME Corrodes aluminum and zinc. Low flash point. Corrosion on fuel injection equipment.
FAME process chemicals Potassium and sodium compound. Solid particles. Blocked nozzles.
Dissolved water in FAME Reversion of FAME to a fatty acid. Fuel filter plugging.
Free water in FAME Corrosion. Sustains bacteria. Corrosion on fuel injection equipment. Sludging.
Free glycerine, mono, and
di-glycerines in FAME Corrodes non-ferrous metals.
Sediments on moving parts and lacquering. Fuel filter clogging.
Fuel injector clogging.
Free fatty acid Corrosion of Zinc plating.
Slats of organic acids.
Organic compound formed. Corrosion on fuel injection equipment.
Fuel filter plugging.
Sediment on components
High viscosity at low temperature Generates excessive localized heat.
Higher stressed components. Fuel injection pump seizures.
Early life issues.
Poor nozzle spray.
Corrosive acids Corrodes all metallic parts. Corrosion on fuel injection equipment.
High molecular organic acids Corrosion of Zinc plating.
Slats of organic acids.
Organic compound formed. Corrosion on fuel injection equipment.
Fuel filter plugging.
Sediment on components
Polymerization products Deposits in fuel mixes Fuel filter plugging. Lacquering formation in hot areas. Recommended Procedures
Prime the fuel system to remove any air. Refer to Operation and Maintenance Manual, Fuel System - Prime for the correct procedure.Check the pressure of the fuel system. Refer to Systems Operation, Testing and Adjusting, Fuel System Pressure - Test for the correct procedure.Check the operation of the fuel injection nozzles. Refer to Systems Operation, Testing and Adjusting, Fuel Injection Nozzle - Test for the correct procedure.To inspect the fuel injection pump, refer to Special Instruction, REHS3767, Inspection of Fuel Injection Pumps on 3054C, C3.3, C4.4 (Mechanical), and C7.1 (Mechanical) Engines for the correct procedure.