101602-2770 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016022770

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-2770 1016022770

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Service parts 101602-2770 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5060

3. GOVERNOR 105400-8330

4. SUPPLY PUMP 105210-4990

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6280

11. Nozzle and Holder 23600-2133

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105030-4300

14. NOZZLE

105015-8590

15. NOZZLE SET

Include in #1:

101602-2770 as INJECTION-PUMP ASSEMBLY

101603-8940 as _

Cross reference number

ZEXEL 101602-2770 1016022770

Zexel num

Bosch num

Firm num

Name

101602-2770

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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 1-4-2-6- 3-5

Pre-stroke mm 3.8 3.77 3.83

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 10.5

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 78 76 80

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.5+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 14 13 15

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 135 145

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
K=14
----------

Speed control lever angle

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

----------
a=9deg+-5deg b=25deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position aa or less, pump speed bb
----------
aa=7.8mm bb=0r/min
----------
a=41deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

Introduction
The problem identified below does not have a permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
There have been instances of faults codes with the DEF Pump, which can lead to an engine derate condition. Affected part numbers for the DEF pumps are:
473-2749 Diesel Exhaust Fluid Pump Gp
473-2750 Diesel Exhaust Fluid Pump Gp
466-8285 Diesel Exhaust Fluid Pump Gp
466-8286 Diesel Exhaust Fluid Pump GpThe codes can be:
Table 1
Event Codes
J1939 Code CDL Code Description
4334-16 E930 (2) Aftertreatment #1 DEF #1 Pressure (absolute) : High - moderate severity (2)
4334-18 E931 (2) Aftertreatment #1 SCR Dosing Re-agent Absolute Pressure : Low - moderate severity (2)
4374-5 E3118 (6) Aftertreatment #1 Diesel Exhaust Fluid Pump Motor Speed : Current Below Normal
5392-31 E1370 (2) Aftertreatment Diesel Exhaust Fluid Dosing Unit Loss of Prime Caterpillar is investigating the root cause of these issues. To support the investigation, Caterpillar is requesting that the following steps are completed, documented, and recorded in SIMSi.Solution
Before starting any troubleshooting, download a Product Status Report (PSR) from the affected engine. Ensure that the PDF and the XML version of the PSR are downloaded, with the Histogram option selected in the Download List.Follow the appropriate troubleshooting steps for the displayed fault codes. Document the results of the troubleshooting tests in the relevant tables. Refer to Tables 2, 3, and 4.If Troubleshoot requests the Pump and Electronics Unit (PEU) to be replaced, conduct the following inspection before removal of the PEU.
Check the DEF for contamination, if the relevant troubleshooting procedure has not instructed you to do so. Refer to "System Operation Testing and Adjusting", Diesel Exhaust Fluid Quality - Test for the correct procedure.
Inspect the DEF tank cap, DEF header filter, DEF pump filter for any visible obstruction
Illustration 1 g06152768
(1) DEF line in
(2) DEF line out
(3) DEF line out let connection
(4) DEF line inlet connection
(5) Injector DEF line
Inspect and photograph both ends of the DEF fluid lines. If the ends of the lines are damaged or swollen, replace the DEF lines. Refer to "Disassembly and Assembly", Diesel Exhaust Fluid Lines - Remove and Install.At the end of the service take another PSR irrespective of outcome. Ensure that the PDF and the XML version of the PSR are downloaded, with the Histogram option selected in the Download List.If the troubleshooting steps have required a component to be changed, hold all replaced components for 30 days for a possible Parts Return Request (PRR). Make sure to include the closed work order paperwork.In every instance submit a SIMSi report, complete with TIB number M0079072, CPI number 359775 and submit through the CPI feedback tool within the SIMSi.
Detailed description of symptom experienced and under what conditions issue occurred
Product Status Report (PSR) before and after troubleshooting. Ensure that the PDF and the XML version of the PSR are downloaded, with the Histogram option selected in the Download List.
Completed Troubleshooting steps tables. Refer to Tables 2, 3, and 4.
Details of DEF tank cap, DEF header filter, DEF pump filter, visual inspection
Photos of DEF fluid lines
Details