101441-9040 ZEXEL 9 400 610 035 BOSCH INJECTION-PUMP ASSEMBLY 9400610035 1014419040 16700t8263

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 035 9400610035

ZEXEL 101441-9040 1014419040

NISSAN-DIESEL 16700T8263 16700t8263

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Service parts 101441-9040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101044-8100

3. GOVERNOR 105542-3690

4. SUPPLY PUMP 105220-4750

5. AUTOM. ADVANCE MECHANIS 105622-1000

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-2130

11. Nozzle and Holder 16600-36W00

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105071-1271

14. NOZZLE

105000-1740

15. NOZZLE SET

Include in #1:

101441-9040 as INJECTION-PUMP ASSEMBLY

Include in #2:

105856-2133 as _

Cross reference number

BOSCH 9 400 610 035 9400610035

ZEXEL 101441-9040 1014419040

NISSAN-DIESEL 16700T8263 16700t8263

Zexel num

Bosch num

Firm num

Name

101441-9040

9 400 610 035

16700T8263 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD25 * K

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

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 1-3-4-2

Pre-stroke mm 2.15 2.1 2.2

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 11.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 36.6 35.6 37.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.2

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8 6.9 9.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point -

Rack position -

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 36.6 36.1 37.1

Remarks
Set full load.

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 800

Advance angle deg. 0.6 0.1 1.1

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 2 1.5 2.5

Timer adjustment_05

Pump speed r/min 1800

Advance angle deg. 5 4.5 5.5

Timer adjustment_06

Pump speed r/min 2000

Advance angle deg. 6 5.5 6.5

Remarks
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)RACK LIMIT: RAL (5)Beginning of idle sub spring operation: L1 (6)With stopper disk. (7)Injection quantity Q = Q1 or less
----------
RAL=14.7-0.3mm L1=9+0.3mm Q1=3mm3/st
----------

Speed control lever angle

B:When boosted N:Normal S:Stop (1)Rack position = aa (2)Rack position corresponding to cc
----------
aa=(1.8)mm bb=15mm
----------
a=1deg+-5deg b=19.5deg+-3deg c=6.5deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(140deg)

Information:

ACTION REQUIRED
After Failure:
1 - Update Engine Software, refer to UENR0611 Troubleshooting ? ECM Software ? Install, ensure to follow the steps to save the Engine Configuration data. Refer to the table in Image 1 to determine the correct engine software file to apply.
2 - Service CCB Filter and replace with new filter, refer to SEBU8727 Operation and Maintenance Manual ? Engine Crankcase Breather element ? Replace.
3 - Remove Diesel Particulate Filter, Refer to UENR0621 Disassembly and Assembly - Diesel Particulate Filter - Remove - Wall Flow Diesel Particulate Filter.
4 - Move the Diesel Particulate Filter Assembly to a suitable work surface.
5 - Refer to UENR0619 Specifications - Diesel Particulate Filter (Wall Flow Diesel Particulate Filter(DPF)), remove V Band Clamps (1)&(4), carefully split assembly and remove DPF Canister element.
6 - Using new DPF Kit Filter, reassemble the Diesel Particulate Filter Assembly noting the alignment marks previously made in Step 3, refer to UENR0619 Specifications - Diesel Particulate Filter (Wall Flow Diesel Particulate Filter(DPF)).
7 - Reinstall the Diesel Particulate Filter assembly, Refer to UENR0621 Disassembly and Assembly - Diesel Particulate Filter - Install - Wall Flow Diesel Particulate Filter.
8 - As the DPF has been replaced, ensure the ?DPF Replacement Reset? procedure is performed using CAT ET, refer to UENR0611 Troubleshooting - Service Tool Features - Components Replacement Resets.
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-3000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 6.0-hour job for Group 1
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-3000 hrs,
0-60 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 6.0-hour job for Group 2
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.