101602-2921 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016022921

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-2921 1016022921

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Cross reference number

ZEXEL 101602-2921 1016022921

Zexel num

Bosch num

Firm num

Name

101602-2921

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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 4.8 4.77 4.83

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 9.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 92.5 91 94

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.9+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10.5 9.5 11.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 135 145

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Stopper bolt setting (3)Set the pump speed at aa (4)Set the pump speed at bb (at delivery)
----------
aa=750r/min bb=900r/min
----------
a=6deg+-5deg b=19deg+-5deg c=0deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal stop (2)Rack position aa or less, pump speed bb (3)Contacts normal side pin (4)Clearance from the pin on the normal side: cc
----------
aa=6.3mm bb=0r/min cc=2.5+-0.5mm
----------
a=53deg+-5deg b=51deg+-5deg c=(6deg)

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

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.
There have been instances of the following diagnostic codes becoming active:
Table 1
J1939 Code CDL Code Code Description
1184-3 3782-3 Engine Turbocharger #1 Turbine Outlet Temperature : Voltage Above Normal
1184-4 3782-4 Engine Turbocharger #1 Turbine Outlet Temperature : Voltage Below Normal
3242-3 2452-3 DPF #1 Intake Temperature Sensor : Voltage Above Normal
3242-4 2452-4 DPF #1 Intake Temperature Sensor : Voltage Below Normal
4360-3 3105-3 Aftertreatment #1 SCR Catalyst Intake Gas Temperature Sensor : Voltage Above Normal
4360-4 3105-4 Aftertreatment #1 SCR Catalyst Intake Gas Temperature Sensor : Voltage Below Normal One root cause of the diagnostic codes has been identified as electrical noise overwriting data on the memory chip of the DPF/SCR intake temperature sensor. Improved sensor firmware has resolved this issue.A fault could not be found with some of the returned parts. A new troubleshooting procedure has been released. Refer to Troubleshooting, Sensor Signal (PWM) - Test.