101602-1502 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016021502

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-1502 1016021502

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Service parts 101602-1502 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9900

3. GOVERNOR 105402-2660

4. SUPPLY PUMP

105210-5250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-1020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5031

11. Nozzle and Holder ME016655

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3590

14. NOZZLE

105017-1040

15. NOZZLE SET

Include in #1:

101602-1502 as INJECTION-PUMP ASSEMBLY

Include in #2:

104057-3320 as _

Cross reference number

ZEXEL 101602-1502 1016021502

Zexel num

Bosch num

Firm num

Name

101602-1502

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)
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 3.5 3.45 3.55

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 A

Rack position 9.7

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 68 67 69

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.8+-0.5

Pump speed r/min 440 440 440

Average injection quantity mm3/st. 7.5 6.2 8.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 65 70

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Supplied with torque spring not set. (4)RACK LIMIT (5)Set idle sub-spring (6)Set the governor spring.
----------
K=10
----------

Speed control lever angle

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

----------
a=(6deg)+-5deg b=(24deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12.5deg
----------
a=(130deg)

Information:

Illustration 17 g03389921
Illustration 18 g03389931
Read the warning and select "Accept" to continue.
Illustration 19 g03389947
Once the reset is completed, a log of the reset is captured and visible as a new row of information in the Diesel Oxidation Catalyst Replacement screen. Selective Catalytic Reduction (SCR) Maintenance on Tier 4 Final Products
Note: Refer to Table 5 for the existing SCR catalyst part number being serviced along with the corresponding new service kit, and the clamp part number required for reassembly.
Table 5
SCR Part Number Service Kit Part Number Required Clamp Part Number
447-8145 N/A 346-0335
447-8143 N/A 346-0335
447-8141 N/A 346-0335
447-8149 N/A 346-0335
447-8147 N/A 346-0335
447-8163 N/A 346-0335
447-8151 N/A 346-0335
375-0989 N/A 346-0335
447-8165 N/A 346-0335
447-8153 N/A 346-0335
447-8161 N/A 346-0335
447-8159 N/A 346-0335
447-8157 N/A 346-0335
447-8169 N/A 346-0335
447-8173 N/A 346-0335
447-8171 N/A 346-0335
447-8167 N/A 346-0335
447-8175 N/A 346-0335 The Aftertreatment SCR Catalyst Replacement procedure must be performed when the SCR Catalyst has been replaced. This is necessary to ensure that the engine meets emissions requirements. Follow the procedure below to reset the SCR Catalyst model in the aftertreatment software.
Connect to Cat® ET.
Illustration 20 g03390636
Connect to "Engine #1 Aftertreatment Controller".
Illustration 21 g03740190
Select "Service" from the top menu and select "Service Procedures".
Illustration 22 g03740205
Select "Aftertreatment #1 SCR Catalyst Replacement" and select "Start".
Illustration 23 g03740210
Select "Reset".
Illustration 24 g03740216
You must read the warning and select "Accept" to continue.
Enter the factory passwords to continue.
Illustration 25 g03740230
Once the reset is completed, a log of the reset is captured and visible as a new row of information in the "Aftertreatment #1 SCR Catalyst Replacement" screen.