101441-9781 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014419781 1679090317


 

Information injection-pump assembly

ZEXEL 101441-9781 1014419781
NISSAN-DIESEL 1679090317 1679090317
101441-9781 INJECTION-PUMP ASSEMBLY
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Service parts 101441-9781 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101044-8310
3. GOVERNOR 105419-1301
4. SUPPLY PUMP 105220-4950
5. AUTOM. ADVANCE MECHANIS 105622-1620
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105148-1120
11. Nozzle and Holder 16600-43G02
12. Open Pre:MPa(Kqf/cm2) 9.8{100}
13. NOZZLE-HOLDER 105078-0050
14. NOZZLE 105007-1130
15. NOZZLE SET

Include in #1:

101441-9781 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101441-9781 1014419781
NISSAN-DIESEL 1679090317 1679090317


Zexel num
Bosch num
Firm num
Name
101441-9781 
101441-9782 
 
1679090317  NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
TD2304 * 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   2.3 2.25 2.35
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   A
Rack position   11.1
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   33.1 32.1 34.1
Max. variation between cylinders %   0 -4 4
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   8.2+-0.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   9.5 8.4 10.6
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   C
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   52 47 57
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   -
Advance angle deg.   0.5
Remarks
Measure speed (beginning of operation).
 
Timer adjustment_02
Pump speed r/min   1100
Remarks
Measure the actual advance angle.
 
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   3 3 3
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101441-9781
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Rack difference from N = N1 (7)Rack difference to N = N2
----------
K=14 N1=1000r/min N2=1000r/min
----------

Speed control lever angle

Test data 101441-9781
F:Full speed I:Idle S:Stop (1)Stopper bolt setting (2)At delivery (3)Confirmation
----------

----------
a=18deg+-5deg b=6deg+-5deg c=32deg+-3deg

Stop lever angle

Test data 101441-9781
N:Pump normal S:Stop the pump.
----------

----------
a=12deg+-5deg b=53deg+-5deg

Timing setting

Test data 101441-9781
(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(100deg)




Information:

General Recommendations and Contamination Control Guidelines for Fuels
Follow all applicable industry standards and all applicable governmental, environmental, and safety guidelines, practices, regulations, and mandates.Note: These general recommendations and guidelines concerning maintenance and care of fuel and fuel storage systems are not intended to be all inclusive. Discuss proper fuel safety and health, handling, and maintenance practices with your fuel supplier. Use of these general recommendations and guidelines does not lessen the engine owners and/or fuel supplier responsibility to follow all industry standard practices for fuel storage and for fuel handling.Note: Where recommendations for draining water and/or sediment and/or debris are stated, dispose of this waste according to all applicable regulations and mandates.Note: Caterpillar filters are designed and built to provide optimal performance and protection of the fuel system components.Clean fuels, as detailed below, are strongly recommended to allow optimal performance and durability of the fuel systems and to reduce power loss, failures, and related down time of engines.Fuels of “ISO 18/16/13” cleanliness levels or cleaner as dispensed into the engine or machine fuel tank should be used. Reduced power, failures and related downtime can result if clean fuels are not used. Fuels of “ISO 18/16/13” are particularly important for new fuel system designs such as Common Rail injection systems and unit injection systems. These new injection system designs utilize higher fuel pressures and are designed with tight clearances between moving parts to meet required stringent emissions regulations. Peak injection pressures in current fuel injection systems may exceed 30,000 psi. Clearances in these systems are less than 5 µm. As a result, particle contaminants as small as 4 µm can cause scoring and scratching of internal pump and injector surfaces and of injector nozzles.Water in the fuel causes cavitation, corrosion of fuel system parts, and provides an environment where microbial growth in the fuel can flourish. Other sources of fuel contamination are soaps, gels, or other compounds that may result from undesirable chemical interactions in the fuels. Gels and other insoluble compounds can also form in biodiesel fuel at low temperatures or if biodiesel is stored for extended periods. An indication of microbial contamination, detrimental fuel additives interactions, or cold temperature gel is very rapid filter plugging of bulk fuel filters or machine fuel filters.To reduce downtime due to contamination, follow these fuel maintenance guidelines in addition to the recommendations given in the "Contamination Control" Chapter in this Special Publication:
Use high-quality fuels per recommended and required specifications (refer to the “Fuel” chapter in this Special Publication).
Do not add new engine oil, waste engine oil or any oil product to the fuel unless the engine is designed and certified to burn diesel engine oil (for example Caterpillar ORS designed for large engines). Engine oils may raise the sulfur level of the fuel and may cause fouling of the fuel system and loss of performance. Engine oils in fuels can also reduce the maintenance intervals of aftertreatment devices in Tier 4 machines.
Use recommended Cat filtration products, including Cat Advanced Efficiency Fuel

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