Information injection-pump assembly
ZEXEL
101451-9200
1014519200
Rating:
Cross reference number
ZEXEL
101451-9200
1014519200
Zexel num
Bosch num
Firm num
Name
101451-9200
INJECTION-PUMP ASSEMBLY
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
2.15
2.1
2.2
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
13.6
Pump speed
r/min
1750
1750
1750
Average injection quantity
mm3/st.
60.8
58.8
62.8
Max. variation between cylinders
%
0
-4
4
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
13.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
52.3
51.3
53.3
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
-
Rack position
13.6
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
50.6
48.6
52.6
Max. variation between cylinders
%
0
-4
4
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
-
Rack position
13.6
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
48
46
50
Max. variation between cylinders
%
0
-4
4
Fixing the rack
*
Injection quantity adjustment_05
Adjusting point
-
Rack position
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
11
8.7
13.3
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Timer adjustment
Pump speed
r/min
600
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
1
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
1.3
0.8
1.8
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
3.8
3.3
4.3
Timer adjustment_05
Pump speed
r/min
1900
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
P:Negative pressure
(1)Pneumatic governor
(2)Mechanical governor
(3)Acting negative pressure: P1
(4)Adjustment speed N1
(5)Beginning of idle sub spring operation: L1
(6)Injection quantity Q = Q1 or less
----------
N1=500r/min L1=10.5+-0.3mm Q1=3mm3/st
----------
----------
N1=500r/min L1=10.5+-0.3mm Q1=3mm3/st
----------
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Fully open
----------
----------
a=33deg+-5deg b=19deg+-3deg c=16.5deg+-5deg
----------
----------
a=33deg+-5deg b=19deg+-3deg c=16.5deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '0' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(50deg)
----------
aa=14deg
----------
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
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
Have questions with 101451-9200?
Group cross 101451-9200 ZEXEL
101451-9200
INJECTION-PUMP ASSEMBLY