Information injection-pump assembly
ZEXEL
101481-9050
1014819050
NISSAN-DIESEL
1671290111
1671290111
Rating:
Cross reference number
ZEXEL
101481-9050
1014819050
NISSAN-DIESEL
1671290111
1671290111
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
2.8
2.75
2.85
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.2
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
67.4
66.3
68.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.8
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
58.2
56.2
60.2
Max. variation between cylinders
%
0
-2.5
2.5
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
8+-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
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_04
Adjusting point
D
Rack position
13.3+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
81
71
91
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1300+50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1600
Advance angle
deg.
1.8
1.3
2.3
Timer adjustment_03
Pump speed
r/min
1800
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Rack difference between N = N1 and N = N2
(4)Confirm that the idle sub-spring does not operate at high idle.
----------
K=10 N1=1500r/min N2=300r/min
----------
----------
K=10 N1=1500r/min N2=300r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the pump speed at aa. ( At delivery )
(2)Stopper bolt setting
(3)Set the pump speed at bb.
----------
aa=1800r/min bb=1500r/min
----------
a=21deg+-5deg b=32deg+-5deg c=9deg+-5deg
----------
aa=1800r/min bb=1500r/min
----------
a=21deg+-5deg b=32deg+-5deg c=9deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=10.5deg+-5deg b=53deg+-5deg
----------
----------
a=10.5deg+-5deg b=53deg+-5deg
0000001501 GOV FULL LOAD ADJUSTMENT
Title1:Full load stopper adjustment
Title2:Governor set speed
LABEL1:Distinguishing
LABEL2:Pump speed (r/min)
LABEL3:Ave. injection quantity (mm3/st)
LABEL4:Max. var. bet. cyl.
LABEL5:Remarks
LABEL6:Distinguishing
LABEL7:Governor set speed (r/min)
LABEL8:Remarks
(1)Adjustment conditions are the same as those for measuring injection quantity.
(2)-
----------
----------
a1=B a2=- r1=1500r/min r2=- Q1=67.4+-1.1mm3/st Q2=- c1=+-2.5% c2=- a3=36 a4=30 r3=1800r/min r4=1500r/min
----------
----------
a1=B a2=- r1=1500r/min r2=- Q1=67.4+-1.1mm3/st Q2=- c1=+-2.5% c2=- a3=36 a4=30 r3=1800r/min r4=1500r/min
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole (position of gear mark 'B') at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(60deg)
----------
aa=14deg
----------
a=(60deg)
Information:
Table 1
Revision Summary of Changes
01 Added prefix S/N:8811-8299 Description Of Change: The new Diesel Exhaust Fluid (DEF) control unit software now used, has been released to improve the priming performance of DEF pumps in cold environments.Adaptable To:
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.The new and former part numbers are listed in Table 2.
Table 2
Required Parts
Qty Dosing Control Unit (DCU) Dosing Control Unit (DCU) Voltage New Part Number Part Name Former Part Numbers(1)
1 Restriction on Hazardous Substance (RoHS) (DCU) 24V 593-7031 Engine Software 567-5763
1 Restriction on Hazardous Substance (RoHS) (DCU) 12V 593-7030 Engine Software 567-5761
1 Non-Restriction on Hazardous Substance (RoHS) (DCU) 24V 593-7033 Engine Software 539-3577
1 Non-Restriction on Hazardous Substance (RoHS) (DCU) 12V 593-7032 Engine Software 539-3576
(1) The former part number listed is for reference only and may differ.The new software is available in the form of a flash file through the Caterpillar Service Information System (SIS). A newer part number may be available. SIS web only displays the latest available flash file.