101602-2910 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016022910

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-2910 1016022910

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Service parts 101602-2910 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9940

3. GOVERNOR 105400-8680

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-8820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5161

11. Nozzle and Holder 23600-2142A

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-8241

15. NOZZLE SET

Include in #1:

101602-2910 as INJECTION-PUMP ASSEMBLY

101603-8600 as _

Cross reference number

ZEXEL 101602-2910 1016022910

Zexel num

Bosch num

Firm num

Name

101602-2910

INJECTION-PUMP ASSEMBLY
14BF PE6AD PE

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 3.45 3.42 3.48

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 11

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 69 67 71

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.5+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 75 75 85

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 (4)Set idle sub-spring (5)Main spring setting
----------
K=6
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Stopper bolt setting (3)When pump speed set at aa (4)Set the pump speed at bb.
----------
aa=750r/min bb=900r/min
----------
a=5deg+-5deg b=18deg+-5deg c=2deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Contacts normal side pin (2)Distance from normal side pin = aa. (3)Normal stop (4)Rack position = bb or less, speed = cc
----------
aa=2.5+-0.5mm bb=7mm cc=0r/min
----------
a=27deg+-5deg b=53deg+-5deg c=(6deg)

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

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
Fuel Injectors in 797F powered Off-Highway Trucks engines are not reaching expected mid-life target. The typical failure mode is a "-2" or a "-7" code on the fuel injectors.Solution
This will be an interim troubleshooting procedure to follow for trucks running with a special test software. Prior to executing this procedure, utilize Cat ® Electronic Technician (Cat ET) or Advisor to verify if any logged codes have been logged. Certain injector diagnostics do not notify the operator or light the check engine light upon activation."Fuel system verification-Test" procedure applies to trucks running with following software versions only.
Engine - LRC 3655600-31 (Test)
Engine - Tier II 5297866-05 (Test)
Engine - HAA (4x2) 3253178-39 (Test)
Engine - Tier II Custom 4727209-12 (Test)Troubleshooting Procedure
Table 1
Troubleshooting Test Steps Values Results
1. Check for Diagnostic Codes
A. Establish communication between Cat® (Electronic Technician) ET and the engine ECM. Cat ET must be configured for Dual Data Link Communications to perform this procedure. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Determine the diagnostic code that relates to an injector. Codes
Result: A -2 code is present.
Repair: Perform the following procedure:
1. Do not clear the diagnostic code.
Access the Fuel System Verification Test by accessing the following display screens:
- Diagnostics
- Diagnostic Tests
- Fuel System Verification Test
3. Perform the Fuel System Verification Test.
If the injector passes the test, the injector is "OK". Cat ET will clear the code.
Result: If the injector fails the test, perform the following procedure:
a. Replace the injector.
b. Flash program the trim file for the new injector into the ECM. Refer to Troubleshooting, "Injector Trim File - Install", if necessary.
c. Perform the Fuel System Verification Test again. This test will clear the active diagnostic code for the new injector. Verify that the original condition has been resolved.
Result: If the test