101608-1472 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081472

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-1472 1016081472

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Service parts 101608-1472 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8391

3. GOVERNOR 105932-2011

4. SUPPLY PUMP 105210-6020

5. AUTOM. ADVANCE MECHANIS 105643-1190

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7522

11. Nozzle and Holder ME072745

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

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE

15. NOZZLE SET 105019-0690

Include in #1:

101608-1472 as INJECTION-PUMP ASSEMBLY

107692-1541 as _

Cross reference number

ZEXEL 101608-1472 1016081472

Zexel num

Bosch num

Firm num

Name

101608-1472

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 11.6

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 99.5 96.5 102.5

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 260 260 260

Each cylinder's injection qty mm3/st. 11.5 9.8 13.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 99.5 98.5 100.5

Basic *

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.7

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 101 97 105

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_05

Adjusting point C

Rack position R2[R1-0. 2]

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 101 97 105

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_06

Adjusting point E

Rack position R1+0.55

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 103.5 99.5 107.5

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2-0.55

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2[R1-0. 2]

Boost pressure kPa 10.7 10.7 10.7

Boost pressure mmHg 80 80 80

Timer adjustment

Pump speed r/min 1000--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 950

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 3.5 3 4

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)Boost compensator stroke: BCL
----------
T1=M18 BCL=0.55+-0.1mm
----------

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=42deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Confirm that speed = aa, rack position = bb and the stopper bolt is set at non-injection at the speed lever's full setting. (2)After setting the stopper bolt with the speed lever in the idle position, confirm non-injection at speed cc. Rack position = dd. (3)R = approximately ee (speed lever full, speed = ff) (4)Free (at delivery)
----------
aa=1400r/min bb=7-0.5mm cc=275r/min dd=(7.5)mm ee=(16)mm ff=0r/min
----------
a=39.5deg+-5deg b=(28deg) c=17deg+-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=42deg+-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:

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.
To improve the reliability and performance of its products, Cat Reman has replaced the entire product line of HI315B Injectors with a version that includes a pre-screen that will capture a portion of the debris trapped in the fuel system during service. The pre-screen will not change the fit, form, or function of the injectors. If a Reman injector order has been filled with new injectors, the new injectors will not have the screen. Injectors both with and without the pre-screen can be used interchangeably.
Illustration 1 g06334704
Table 1
H1315B Injectors
New Part Number Reman Part Number
387-9426 20R-8071
387-9427 20R-8066
387-9428 20R-8059
387-9429 20R-8058
387-9430 20R-8057
387-9431 20R-8069
387-9432 20R-8065
387-9433 20R-8064
387-9434 20R-8063
387-9436 20R-8068
387-9437 20R-8062
387-9438 20R-8060
387-9439 20R-8061
387-9440 20R-8070
387-9441 20R-8067