101608-1500 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016081500

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-1500 1016081500

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Cross reference number

ZEXEL 101608-1500 1016081500

Zexel num

Bosch num

Firm num

Name

101608-1500

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

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)Torque spring does not operate. (4)Main spring setting (5)Set at delivery (6)Set idle sub-spring
----------
K=13
----------

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=(18deg)+-5deg d=(12deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

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

Information:

Illustration 9 g06426461
(1) For 323, 330, and 330GC machines use 580-1893 Plate As / For 336GC machines use 581-5268 Plate As
(Q) Bolt and washer
(R) Plate
Install plate assembly (1) using plate (R), bolt, and washer (Q). Tighten the bolts to 55 10 N m (41 7 lb ft). Refer to Illustration 9.
Illustration 10 g06426462
(7) 365-0162 Special Connector
(F) Injector
Install special connector (7) to injector (F). Refer to Illustration 10.
Illustration 11 g06426463
(2) 573-8722 Tank
(8) 3S-2093 Cable Strap
(E) Hose
(M) Harness
Connect hose (E) to tank (2). Refer to Illustration 11.
Illustration 12 g06426465
View of area T
(1) For 323, 330, and 330GC machines use 580-1893 Plate As / For 336GC machines use 581-5268 Plate As
(P) Clip
(S) Bolt and washer
(D1) 45 Degree
Install clip (P) using bolt and washer (S), torque to 28 7 N m (248 62 lb in). Refer to Illustration 12.
Secure the harness (M) using cable strap (8). After tie up, cut all the surplus of strap. Refer to Illustration 11.
Reinstall upper cover (A) and close the upper cover (B). Refer to Illustration 1 and Illustration 2.Replacement Procedure for 336 Excavators
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 3
Required Parts
Item Qty Part Number Part Name
1 1 471-9926 Tank
2 1 581-3324 Plate As
3 1 327-0325 Cable Strap
Illustration 13 g06426466
(A) Upper cover
(B) Upper cover
Remove the upper cover (A) and open the upper cover (B). Refer to Illustration 13.
Illustration 14 g06426467
(C) Tank assembly
(E) Hose
(F) Hose
(G) Strap
Disconnect hose (E) and hose (F) from tank assembly (C). Cut and remove the strap (G). Refer to Illustration 14.
Illustration 15 g06426468
(C) Tank assembly
(H) Bolt and washer
(J) Bolt and washer
(K) Plate assembly
Remove tank assembly (C) by loosening the bolt and washer (H). Refer to Illustration 15.
Remove plate assembly (K) by loosening the bolt and washer (J). Refer to Illustration 15.
Illustration 16 g06426469
(F) Hose
(D1) 10.0 mm (0.4 inch)
Cut and remove the end of hose (F) by 10.0 mm (0.4 inch). Refer to Illustration 16.
Illustration 17 g06426470
(1) 471-9926 Tank
(2) 581-3324 Plate As
(3) 327-0325 Cable Strap
(E) Hose
(H) Bolt and washer
(J) Bolt and washer
(F) Hose
Install the plate assembly (2) and tank (1) using bolt and washer (J) and bolt and washer (H). Refer to Illustration 17.
Connect hose (E) and hose (F) to tank (1). Add cable strap (3) to secure hose. After tie up, cut all the surplus of strap. Refer to Illustration 17.
Reinstall upper cover (A) and close the upper cover (B). Refer to Illustration 13.