101607-6720 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016076720

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-6720 1016076720

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Cross reference number

ZEXEL 101607-6720 1016076720

Zexel num

Bosch num

Firm num

Name

101607-6720

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 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

RED3 control unit part number 407910-2 470

RED3 rack sensor specifications mm 15

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

Rack position (8.9)

Vist V 2.22 2.22 2.22

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 81.5 80.5 82.5

Max. variation between cylinders % 0 -3 3

Basic *

Injection quantity adjustment_02

Rack position (6.5)

Vist V 2.7 2.6 2.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 10.8 9.2 12.4

Max. variation between cylinders % 0 -15 15

Governor adjustment

Pump speed r/min 970--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 920

Advance angle deg. 0.5

Governor adjustment_03

Pump speed r/min -

Advance angle deg. 1 0.5 1.5

Remarks
Measure the actual speed.

Governor adjustment_04

Pump speed r/min 1160

Advance angle deg. 1 0.5 1.5

Governor adjustment_05

Pump speed r/min 1420

Advance angle deg. 7 6.5 7.5

Remarks
Finish

Test data Ex:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=1mm bb=16mm
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a=31deg+-5deg b=29deg+-5deg

0000000901

(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=7deg
----------
a=(3deg)

Stop lever angle

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 15 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
The diesel exhaust fluid (DEF) quality sensors are susceptible to seeing the following fault codes.
Table 1
J1939 CDL Code Description
3516-2 3100-2 Aftertreatment #1 DEF Concentration: Erratic, Intermittent or Incorrect
3516-12 3100-12 Aftertreatment #1 DEF Concentration: Failure
3516-16 E1365 High Aftertreatment #1 DEF Concentration
3516-18 E1364 Low Aftertreatment #1 DEF Concentration Solution
The latest software available in SIS has improvements in it related to the DEF quality sensor and these fault codes.
Ensure that the latest engine and aftertreatment software is installed prior to any hardware replacements.
Ensure that the latest DCU software is installed ( 539-3577 Engine Software (24V DCU) or 539-3576 Engine Software (12V DCU)).
In addition to the troubleshooting for these fault codes in SIS web, ensure that DEF quality is checked with both a refractometer and the 466-8796 Test Strips as outlined in Diesel Exhaust Fluid Quality - Test procedure in SIS.
Keep the DEF tank full when machine/engine will not be operated for an extended period of time to help reduce manifold exposure to ammonia gases in the DEF tank.Have seen cases of contamination where the test strips will not detect it if contamination is not hydrocarbon-based. In these instances, the DEF will appear to be cloudy when doing a visual comparison to a good, clean DEF sample.While working through issues related to these particular fault codes, email Blunier_Derek_W to provide troubleshooting information and documentation as to what was found.Information to Provide
PSRPT with histograms
Application History File
All troubleshooting resultsIf the DEF manifold does get replaced, provide the following:
Dealer code
Workorder number
Serial number
Hours at repair
DEF sample collected from top level of tank to be returned along with the DEF manifoldA Send It Back (SIB) will be created to get the DEF manifold returned.Downloading an Application History File
Illustration 1 g06233931
Click the appropriate ECM.
Click "Information".
Click "Warranty Report".
Illustration 2 g06233935
Click "ECM Information".
Click the "Yes" button.
Illustration 3 g06233938
Click "Additional Service".
Click the "Save" button.