101607-9470 ZEXEL 9 400 615 759 BOSCH INJECTION-PUMP ASSEMBLY 9400615759 1016079470

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 759 9400615759

ZEXEL 101607-9470 1016079470

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104138-1022 as _

Cross reference number

BOSCH 9 400 615 759 9400615759

ZEXEL 101607-9470 1016079470

Zexel num

Bosch num

Firm num

Name

101607-9470

9 400 615 759

DAEWOO

INJECTION-PUMP ASSEMBLY
DB58 * K

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

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive 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 11.1

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 73.5 71.9 75.1

Max. variation between cylinders % 0 -2.5 2.5

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

Average injection quantity mm3/st. 9 7.7 10.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.1)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 73.5 72.5 74.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 94 90 98

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 90 100

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1520

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=K82
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=40deg+-5deg b=(42deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=45mm
----------
a=25deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(2deg)

Information:

Introduction
Do not perform any procedure that is outlined in this Special Instruction until you have read and understand the information contained in this document.Required Parts
Table 1
Required Parts
Item Qty Part Number Part Name
1 1 360-9664 Tool Kit
2 1 399-7930 Cap Kit Testing Procedure
Use Caterpillar Electronic Technician (ET) to perform a "Manual Diesel Particulate Filter Regeneration".
Once the regeneration is complete, wait for the engine to drop to idle before shutting off the engine. The regeneration takes approximately 20 minutes.
Allow the system to cool down before handling.
While waiting for the exhaust to cool, perform the following actions.
Record the "Idle Speed Limit". Use Cat ET to change the "Idle RPM Limit" to 2100 rpm.
Use Cat ET to disable the automatic regeneration. A "Check Engine" light with active code 3714-31 will be present.
Remove the exhaust piping after the DPF. Install the 3 inch orifice plate for C13 and C15 engines. Install the 2 inch orifice plate for C7 and C9 engines. The 2 inch orifice plate is part of the 399-7930 Cap Kit .For a DPF with a dual outlet, use the solid cap that is provided and cap one of the outlets.For a dual DPF with one end cap, use a 313-3496 Plug to plug the drain hole, one 3L-7055 Pipe Connector , one 001-6449 Connector , and filter paper. Remove the delta P sensor from each DPF. Insert one 3L-7055 Pipe Connector , one 001-6449 Connector , and filter paper into each DPF. This action allows both diesel particulate filters to be tested at the same time.Note: The 313-3496 Plug , the 001-6449 Connector , and the 3L-7055 Pipe Connector is not included in the kit.
Start the engine. Run the engine at 2100 rpm for a minimum of 10 minutes to stabilize DPF temperatures.
Shut down the engine and install the filter holder in the drain port.Note: Do not wait more than 10 minutes after the engine has shut down to install the filter.
Run the engine at 2100 rpm for 20 minutes.
Shut down the engine and remove the filter holder. Use proper personal protective equipment to remove the filter holder.Note: Do not wait more than 10 minutes after the engine has shut down to remove the filter holder.
Warning: The filter holder will still be hot.
Wait for the filter holder to cool down before disassembly.
Carefully disassemble the filter holder to prevent contamination.
Tip the fitting over on a clean surface to remove the filter paper.
Handle the filter paper with clean hands. Only handle the filter paper by the edges.
Compare the stained area in the center of the filter paper to the color coded sheet that is provided.If the stained area of the filter paper is as dark or darker than colored circle 2, then the DPF may have to be replaced.If a DPF fails the test, then contact the DPF hotline to verify the failure and have a new DPF released.