101681-9450 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016819450


 

Information injection-pump assembly

ZEXEL 101681-9450 1016819450
101681-9450 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101681-9450 1016819450


Zexel num
Bosch num
Firm num
Name
101681-9450 
 
   
INJECTION-PUMP ASSEMBLY
6102Q *

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   132424-0620
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   2.2 2.15 2.25
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   10.8
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   54.2 52.7 55.7
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   7+-0.5
Pump speed r/min   325 325 325
Average injection quantity mm3/st.   6.6 5.3 7.9
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   -
Pump speed r/min   550 550 550
Average injection quantity mm3/st.   45 42.1 47.9
Max. variation between cylinders %   0 -6 6
Fixing the lever   *
Remarks
After startup boost setting
 
Injection quantity adjustment_04
Adjusting point   E
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   65 65
Fixing the lever   *
Remarks
After startup boost setting
 
Timer adjustment
Pump speed r/min   550--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   500
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   700
Advance angle deg.   1 0.5 1.5
Timer adjustment_04
Pump speed r/min   1100
Advance angle deg.   2.7 2 3.4
Timer adjustment_05
Pump speed r/min   1400
Advance angle deg.   4.4 3.7 5.1
Timer adjustment_06
Pump speed r/min   1600
Advance angle deg.   5.4 4.7 6.1
Timer adjustment_07
Pump speed r/min   -
Advance angle deg.   6 6 6
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101681-9450
N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Set using the excess fuel device for starting. (3)Rack difference between N = N1 and N = N2
----------
DL=5.2-0.2mm N1=1500r/min N2=900r/min
----------

0000000901

Test data 101681-9450
F:Full load I:Idle
----------

----------
a=16deg+-5deg b=33.5deg+-3deg

Stop lever angle

Test data 101681-9450
N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=71deg+-5deg

Timing setting

Test data 101681-9450
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

Registering a New DEF Injector Injection Timing, Serial Number, and Part Number
Record the DEF injector trim code & part number.
Illustration 10 g06075057
(6) DEF Injector Injection Timing
(7) Part Number
Illustration 11 g06075059
(8) DEF Injector Serial Number
Record the DEF injector Serial Number.
Go to SIS.
Select "View More".
Select "Additional Service Information".
Select "C2.4, C3.3B" and "C3.8 Downloads".
Select ECU Trim Data Registration (Injector, Injection Timing, or DEF Injector).
Illustration 12 g06070579
Input the 6 or 7-digit code engine serial number. Refer to "General Information" to locate the serial number.
Click the button to select the engine.
Enter the new DEF injector part number, Serial number, and injection timing.
Illustration 13 g06075064
Once the new DEF injector Part number, Serial number and Injection timing values have been registered you may follow the DCU flashing procedure to obtain the new DPK flash file found in REHS9223, "Electronic Control Module (ECM) & Dosing Control Unit (DCU Flashing Procedure for the C2.4, C3.3B and C3.8 Engines".Note: Following the above procedure will ensure that any future DCU reflashing will flash the correct DEF injector information.New DEF Injector Install within Electronic Technician (ET)
The Caterpillar Electronic Technician (ET) is used to load injector trim files into the Engine Control Module (ECM).Replacing a DEF Injector
A new DEF Injection Timing Correction must be loaded into the DCU if an injector is replaced through Caterpillar Electronic Technician (ET).Replacing the DCU
Prior to replacing a DCU, It is recommended to download a Product Status Report for documentation of the DEF Injector. After replacing the DCU, ensure the DEF injector trim codes in the new DCU match the saved Product Status Report.
Establish communication between Cat ET and the engine ECM. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
Select the following menu options on Cat ET:
Service
Calibrations
Diesel Exhaust Fluid Controller #1
Injector Code Calibration
Illustration 14 g06070577
Select Injector 1
Illustration 15 g06070578
Enter the new "DEF Injection Timing" Current Value.
Click the "Change" button.Registering (Fuel) Injection Timing Correction
The following steps are to be followed when the fuel injection timing correction procedure has been performed and the engine ecm must be updates with the new value.Note: This procedure is only performed if the crankshaft, gear case, crank gear, or flywheel is replaced. Refer to the following engine specific Special Instructions for determining Injection Timing Correction.C2.4 , M0084937C3.3B , M0084939C3.8 , M0084935
Illustration 16 g06220029
Got to SIS web. Select C2.4, C3.3B, and C3.8 Downloads.
Illustration 17 g06220033
Select ECU and DCU Trim Data Registration.
Illustration 18 g06220036
Engine Serial Number and select search. Engine Serial Number is case-sensitive.
Illustration 19 g06220038
Click the circle (indicated by red arrow) and wait for the screen to change.
Illustration 20 g06220042
Scroll down until Injection Timing Correction is displayed. Enter new value, scroll to the bottom of page, and select Register.
Once the new Injection Timing Correction value has been registered a new DPK file will need to be downloaded and flashed to the Engine ECM. Refer to , REHS9223, "Electronic Control Module (ECM) & Dosing Control Unit (DCU) Flashing Procedure for the C2.4, C3.3B and C3.8 Engines".

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