101607-1470 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016071470

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-1470 1016071470

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Service parts 101607-1470 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-8960

3. GOVERNOR 105490-5600

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105643-0730

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5540

11. Nozzle and Holder ME047437

12. Open Pre:MPa(Kqf/cm2) 17.7{180}

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE 105015-6230

15. NOZZLE SET

Include in #1:

101401-7650 as _

101607-1470 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101607-1470 1016071470

Zexel num

Bosch num

Firm num

Name

101607-1470

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 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 4.2 4.15 4.25

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 B

Rack position 10

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 88.3 87.3 89.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.1+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 13.7 12.2 15.2

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point F

Rack position 12.5+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 75 115

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 700

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 650

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)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (N = N1) (5)Main spring setting (6)Damper spring setting (7)Set idle sub-spring (8)Microswitch adjustment unnecessary.
----------
RT=1 TH=2.7mm SXL=11+-0.1mm N1=340r/min
----------

Speed control lever angle

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

----------
a=18deg+-5deg b=3deg+-5deg

0000000901

F:Full load (1)Fix the lever at the full load position
----------

----------
a=16deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set stopper bolt so that rack position = aa (after adjusting, apply red paint).
----------
aa=5-0.5mm
----------
a=57deg+-5deg b=55.5deg+-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=14deg
----------
a=(1deg)

Information:

ACTION REQUIRED
New DEF system Software is available that reduces the risk of an internal DEF injector leak by improved temperature management. Please update the DEF system software at the next opportunity.
Ensure that all adjustments and repairs that are carried out to the Diesel Emission Fluid (DEF) system are performed by authorized personnel that have the correct training. Before beginning ANY work on the DEF system, refer to Operation and Maintenance Manual, "General Hazard" for safety information.
Check that the engine software is the latest version before updating the DEF pump software.
If the engine software is not the latest version, update the Engine Software first.
If needed, update the engine software with the latest available in SIS Web.
Flash the DEF Pump ECM with the software listed in the Parts Needed or latest available in SIS Web.
For flash programming of the ECM software, refer to Troubleshooting, "ECM Software - Install".
Replace the DEF Injector. Refer to Disassembly and Assembly Manual, "Diesel Exhaust Fluid Injector - Remove and Install".
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-5000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job for Group 1
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-5000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 2.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.