101607-1530 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016071530

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-1530 1016071530

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101607-1530 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 101607-1530 1016071530

Zexel num

Bosch num

Firm num

Name

101607-1530

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 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 850 850 850

Each cylinder's injection qty mm3/st. 72.5 70.3 74.7

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 8.3 7.1 9.5

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 850 850 850

Average injection quantity mm3/st. 72.5 71.5 73.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 79.5 75.5 83.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.65

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 71.5 67.5 75.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position 14.8+-0. 2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 100 140

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.9 0.4 1.4

Timer adjustment_03

Pump speed r/min 1380

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)RACK LIMIT
----------
T1=F24
----------

Speed control lever angle

F:Full speed I:Idle (1)R = aa (2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=24deg+-5deg b=(44deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Pump speed = aa and rack position = bb (non-injection rack position) (2)Set the stopper bolt (confirm non-injection). (3)Corresponding to rack position = cc. (4)Free (at shipping) (5)Use the hole above R = dd
----------
aa=1400r/min bb=6.9-0.5mm cc=15mm dd=40mm
----------
a=36.5deg+-5deg b=(25deg) c=13.5deg+-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=(44deg)+-3deg c=24deg+-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=11deg
----------
a=(0deg)

Information:

This is a 4.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Step 1: Ensure CEM has cooled prior to beginning work. Use a temp gun to ensure that the temperature of the injector is at a safe to handle temperature.
Image1.1.1
Step 2: Once the CEM is at a safe temperature to begin work, remove air and DEF line connections at the injector. Ensure all permits and appropriate scaffolding or man-lift type equipment with sufficient personnel are on site or available if needed. This procedure may require two individuals with all the required PPE to handle the weight and distance to reach for work to be performed.
Image1.2.1
Step 3: Remove eight bolts and remove injector assembly from the CEM. This step may require two individuals due to the weight of the injector.
Step 4: Remove the nozzle group from the injector.
Image1.4.1
Step 5: Apply Loctite (nickel free) dry film anti-seize on the threads of the 352-0865 nozzle group. Ensure that only the threads receive anti-seize as the nozzle could suffer plugging if anti-seize contaminates the tip. Install the nozzle group with a new gasket onto the injector group and tighten to 30 +/- 2 Nm.
Image1.5.1
Step 6: Reinstall the injector with new nozzle and new gasket into the CEM matching alignment notches and tighten the eight (8) mounting bolts to standard torque. This step may require two individuals due to the weight of the injector.
Image1.6.1
Step 7: Using a stamping die set, the old injector part number must be removed. This can be accomplished using the X stamp and stamping out all of the part numbers (XXXXXXXX) or a grinder can be used to permanently remove the part number.
Step 8: Using the stamping die set, stamp part number 549-2925 on the flange of the injector as shown in Image 1.6.1.
Step 9: Perform ECM replacement and save all parameters in Product Status Report. Install software part number 590-2884 or latest available on SIS Web into the dosing cabinet ECM.
Step 10: Once flash is complete, perform a complete power cycle of the package and power up: Engine, Control Panel and Dosing system simultaneously. Verify flash and settings are correct in Aftertreatment configuration.
Please note that re-commissioning of the SCR system is not required after the software update if the system has already been commissioned.
Step 11: If Air Assist pressure is low or high then Air Manifold Regulator Adjust Procedure may be required:
Tools Required to Adjust Regulator in Dosing Cabinet:
? Laptop with CatET
? CA3
? 4mm Allen Key
? 8mm Socket to remove access panels
? 0-150 psi gauge with 9/16-18 JIC tees to measure pressure at dosing cabinet inlet
Air Regulator Adjustment Procedure
? Connect CatET to cabinet
? Record air pressure supply before air manifold with a gauge
? Adjust air supply to dosing cabinet if not in spec
? Air Supply in spec. continue
? In ET Override screen, Monitor Air Assist Pressure
? In ET Override screen, Override Air Assist and DEF Return valves
? Monitor and Record Air Assist pressure: Target is 65psi with both valves Override to