101502-9004 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1015029004

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101502-9004 1015029004

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Service parts 101502-9004 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101050-8022

3. GOVERNOR 105410-8640

4. SUPPLY PUMP 105220-5480

5. AUTOM. ADVANCE MECHANIS 105621-0430

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7370

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 15.7(160)/22.1(225)

13. NOZZLE-HOLDER 105031-4990

14. NOZZLE 105015-7140

15. NOZZLE SET

Include in #1:

101502-9004 as INJECTION-PUMP ASSEMBLY

101692-3320 as _

Cross reference number

ZEXEL 101502-9004 1015029004

Zexel num

Bosch num

Firm num

Name

101502-9004

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 134424-4420

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-5-4- 2

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 72 71.5 72.5

Difference between angles 2
Cal 1-5 deg. 144 143.5 144.5

Difference between angles 3
Cal 1-4 deg. 216 215.5 216.5

Difference between angles 4
Cyl.1-2 deg. 288 287.5 288.5

Injection quantity adjustment

Adjusting point A

Rack position 10.1

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 74 72.5 75.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.2+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 10 8 12

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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)Set idle sub-spring (4)Main spring setting (5)Rack difference from N = N1
----------
K=14 N1=1200r/min
----------

Speed control lever angle

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

----------
a=21deg+-5deg b=37deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=35mm
----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

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

----------
a=(120deg)

Information:

Image1.5.1
2. Use 4 new grommets (MCI part number 97-2246-00002 (Dealer Order)) per bus. Grommets are to be installed between the clamp and chassis frame at same location as originals.
3. Clean existing exhaust inlet pipe with wire brush for reuse. Install new Exhaust clamps (Dealer Order).
4. Clean existing exhaust Outlet pipe with wire brush for reuse. Install new Exhaust clamps (Dealer Order).
5. Use a floor jack or transmission jack with CCRT properly secured to lift into place. Place a pipe clamp loosely over the inlet socket. Use the jack to raise the CCRT assembly into position. Insert exhaust pipe elbow into inlet socket. Tighten the clamp bolt to a torque of approximately 50 lb ft. Refer image 1.5.1.
Image1.6.1
6. Provide adequate clearance to Pro Heat exhaust pipe. Mounting brackets will have 1/2 inch slotted bolt holes. Orient to provide needed clearance. Refer image 1.6.1.
Image1.7.1
7. Install Thermocouple.
- Apply a thin coat of anti-seize to the threads of the Male Run Tee and thread it into the boss on the CCRT inlet. Image 1.7.1 shows a completed installation.
- All the parts used from Step 7 to Step 10 are included in the 219-7990 Installation Kit.
Image1.8.1
8. Insert the reducer fitting into the Tee fitting in line with the boss (Image 1.8.1). Tighten the lock nut (also use the Lock Washer) on the Tee until it is finger tight and then tighten it 1 1/4 turns with a 9/16" wrench.
Image1.9.1
9. Insert the thermocouple into the reducer as far as it will go, then pull it back 1/4 inch (Image 1.9.1). Tighten the lock nut finger tight and then tighten 1 1/4 turns with a 7/16" wrench. If necessary, the thermocouple may be bent ONCE to avoid any interference. Do not bend the thermocouple past 90 degrees.
NOTE. JM instructions instruct to insert probe and withdraw one inch. For this installation, insert probe and withdraw 1/4 inch to allow accurate temperature measurement of the exhaust.
Image1.10.1
10. Insert the copper tubing into the fitting on the Tee that is at a 90 degree angle to the boss (Image 1.10.1). Tighten the fitting on the Tee until it is finger tight. Then tighten it 1 1/4 turns with a 9/16" wrench.
Image1.11.1
Image1.11.2
11. Route the cable and copper tube and the secure cable with 6K0806 Cable Straps as shown. It is important to use these cable straps so the tube and cable are oriented in a way that they do not rub against the frame.
Install P brackets every two to three feet as needed. Refer in Image 1.11.2.
12. Install 271-6537 CCRT Diagnostic Module using Bolts (4M5282), Washers (8T4205), nut (6V8185) and Lock Washer (3B4504). Use carbide tip drill bit for drilling in stainless steel.
Image1.13.1
13. Install 282-0031 Remote Display monitor lights along with dealer fabricated Remote Display Bracket. Use self tapping screws (90064A581), Splice (1364877), Washer (4B4274), Locknut (031049) and screw (4B1232).
Image1.14.1
14. Connect power using 3A Fuse.
15. Install existing Pin insulator on the weatherpack plug that connects to the OEM harness at the firewall that provides power to the CRT module.
16. Download