101502-9014 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1015029014

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101502-9014 1015029014

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Service parts 101502-9014 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101050-8032

3. GOVERNOR 105410-8630

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:

101502-9014 as INJECTION-PUMP ASSEMBLY

101695-3340 as _

Cross reference number

ZEXEL 101502-9014 1015029014

Zexel num

Bosch num

Firm num

Name

101502-9014

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 9.5

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 59.2 57.7 60.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.1+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8.9 6.9 10.9

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=12 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:

If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Dealer to perform most economical repair.
Description____________________________SMCS Code___Hours
Wash___________________________________1091-074 ___0.2
Inner fender __________________________7252-010 ___0.2
R&I DPF _______________________________108F-010 ___1.2
program ECM - program DPF serial # ,
ASH reset, factory passwords __________1901-591 ___0.2
Test after Repair _____________________108F-030 ___0.2
This letter is to be performed during a recommended ash service as stated in Media number SEBU8087. Ash cleaning is a part of the recommended maintenance of the engine, customer is responsible for the labor required to remove and install the DPF.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1. Wash debris from Diesel Particulate Filter (DPF) as necessary.
Image1.1.1
2. Remove the Fender (A): Loosen and remove the nuts and bolts from the fender of the truck. Retain the fender and fasteners for reuse. Refer to Image 1.1.1.
Image1.2.1
3. Remove the Step (B): Loosen and remove fasteners from the step of the truck. Retain the step and fasteners for reuse. Refer to Image 1.2.1.
Image1.3.1
Image1.3.2
4. Remove the Pipe Clamps: Loosen and remove clamps from the Inlet Pipe (C)& Outlet Pipe (D) of the DPF?s. Refer to Image 1.3.1 & Image 1.3.2
Image1.4.1
5. Remove tubes (E) and sensor box mounting bolts (F) to unplug sensor box connection. Refer to Image 1.4.1.
Image1.5.1
6. Remove DPF mounting bolts: Loosen and remove fasteners from the mounting of the DPF. Retain the mounting and fasteners for reuse. No jack will be used to hold DPF, DPF is supported by air tank brackets. Properly support DPF until it rests on the bracket. Refer to Image 1.5.1.
Image1.6.1
7. Slide the DPF forward and remove. Remove the CGI pipe (G) after the DPF has been removed. Refer to Image 1.6.1.
Image 1.7.1 shows the chassis after the welded DPF has been removed.
Image1.7.1
Image1.7.2
8. Install the Clamped DPF with mounting bolts (reuse the bolts). Install the new 330-4036 CGI Pipe for Group 1 & Group 2 with the 304-3048 Clamp. Check Inlet, Outlet and CGI pipes alignment, mounting brackets should be aligned with OEM brackets.
Refer OEM guidelines for connecting Inlet & CGI connections.
Image 1.7.2 shows the clamped DPF after it has been installed in the chassis.
9. Install the step and fender that were removed in Step 2 and Step 3.
10. Reset the engine ash model. Refer Media Number RENR9705.
11. Start the engine and use CAT ET to ensure that the status parameter Diesel Particulate Trap #1 Differential Pressure has a value greater than zero. Also ensure status parameters Diesel Particulate Trap #1 Intake Temperature, and Diesel Particulate Trap #1 Outlet Temperature show reasonable values and increase with the rising exhaust temperatures.