101403-9042 ZEXEL 9 400 612 108 BOSCH INJECTION-PUMP ASSEMBLY 9400612108 1014039042 1670019d21


 

Information injection-pump assembly

BOSCH 9 400 612 108 9400612108
ZEXEL 101403-9042 1014039042
NISSAN-DIESEL 1670019D21 1670019d21
101403-9042 INJECTION-PUMP ASSEMBLY
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Service parts 101403-9042 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101041-9430
3. GOVERNOR 105921-9851
4. SUPPLY PUMP 105220-7060
5. AUTOM. ADVANCE MECHANIS 105671-0610
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105118-6620
11. Nozzle and Holder 16600-19D20
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105048-4270
14. NOZZLE 105017-2440
15. NOZZLE SET

Include in #1:

101403-9042 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 108 9400612108
ZEXEL 101403-9042 1014039042
NISSAN-DIESEL 1670019D21 1670019d21


Zexel num
Bosch num
Firm num
Name
101403-9042 
9 400 612 108 
1670019D21  NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
FD46TA K 14BD INJECTION PUMP ASSY PE4AD 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   134424-4120
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
Tester oil delivery pressure kPa   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-3-4-2
Pre-stroke mm   3.2 3.15 3.25
Rack position
Point A
  R=A
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-3
deg.   90 89.5 90.5
Difference between angles 2
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 3
Cyl.1-2
deg.   270 269.5 270.5
Injection quantity adjustment
Adjusting point   -
Rack position   14.1
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   100 98.4 101.6
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   H
Rack position   9.9+-0.5
Pump speed r/min   325 325 325
Average injection quantity mm3/st.   13 11.2 14.8
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(14.1)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   100 99 101
Basic   *
Fixing the lever   *
Boost pressure kPa   59.3 59.3
Boost pressure mmHg   445 445
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   115.5 111.5 119.5
Fixing the lever   *
Boost pressure kPa   59.3 59.3
Boost pressure mmHg   445 445
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   R2-1.6
Boost pressure kPa   14 12.7 15.3
Boost pressure mmHg   105 95 115
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   R2(R1-0. 15)
Boost pressure kPa   46 46 46
Boost pressure mmHg   345 345 345
Timer adjustment
Pump speed r/min   780--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   730
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1550
Advance angle deg.   5.7 5.2 6.2
Timer adjustment_04
Pump speed r/min   -
Advance angle deg.   7 6.5 7.5
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101403-9042
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=N79 BCL=1.6+-0.1mm
----------

Speed control lever angle

Test data 101403-9042
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=71.5deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101403-9042
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=15mm
----------
a=29deg+-5deg b=10deg+-5deg

Timing setting

Test data 101403-9042
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=8deg
----------
a=(50deg)




Information:

Lubricant Viscosity Chart
Commercial Oils
Failure to follow the commercial oil recommendations can cause shortened engine life due to piston carbon deposits, liner bore polish and/or abnormally higher increasing oil consumption.API CC and CD oils are unacceptable in this Caterpillar diesel engine.
* API specifications CF-4, CF-4/SH or CF-4/SGThe oil specifications above provide guidelines for the selection of commercial products. They may require shortened oil change intervals as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S). The same viscosity grades are recommended for commercial oils as for CAT oils.Lubricant Total Base Number (TBN)
New engine oil must have a TBN of 20 times (for Precombustion Chamber engines) and 10 times (for direct injection engines) the percent fuel sulfur as measured by ASTM (American Society if Testing Materials) D2896 method. Refer to the Fuel Specifications in this manual for additional information.Caterpillar DI Engines Only
Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The fuel sulfur neutralization of today's new oil formulations along with direct injection (DI) system engines are more effective. Field results indicate that direct injection combustion (DI) systems and the oils now recommended for these engines will operate at an oil TBN equal to 10 times the fuel sulfur above 0.5% and using API CF-4 oils. Caterpillar requirements reflect this value of 10 times for DI engines.Caterpillar still maintains 20 times TBN value for precombustion chamber (PC) engines when using API CD, CE or CF-4 oil when related to fuel sulfur above 0.5%. Used oil analysis should be a part of the overall program to provide the assurance that a particular engine installation with all its parameters (engine, oil, operation, maintenance and fuel) are under control. Engines built prior to 1990 can continue to use DEO-CD single grade viscosity oil or commercial oils provided the engine operates to user satisfaction. Consult with your Caterpillar dealer for the latest lubrication recommendations.Synthetic Base Stock Oils (SPC)
The performance characteristics of the oil depends on the base oil and the additives. The additives in the oil will vary according to the properties of the base oil and the environment in which the oil will perform its function.Synthetic base stock oils are acceptable for use in Caterpillar engines if these oils meet the performance requirements specified for a particular compartment. The performance requirements for engines using synthetic oils is API CF-4 with API CE as an alternative.The use of a synthetic base stock oil does NOT allow extension of the oil drain period simply because of the use of synthetic oil. Any drain period extension must be validated by S O S (oil analysis and test evaluation) to ensure no excessive component wear occurs in a particular application.The synthetic oils have naturally low pour points

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