101481-9090 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014819090 16700t9303

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101481-9090 1014819090

NISSAN-DIESEL 16700T9303 16700t9303

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Cross reference number

ZEXEL 101481-9090 1014819090

NISSAN-DIESEL 16700T9303 16700t9303

Zexel num

Bosch num

Firm num

Name

101481-9090

16700T9303 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD33T * 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

Overflow valve 132424-0620

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

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 10.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 70.4 68.8 72

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.6+-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 *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.4)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 70.4 69.4 71.4

Basic *

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.4)

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 78.2 74.2 82.2

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Boost compensator adjustment

Pump speed r/min 1100 1100 1100

Rack position R1-1.8

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

Boost compensator adjustment_02

Pump speed r/min 1100 1100 1100

Rack position R1-1

Boost pressure kPa 32 30.7 33.3

Boost pressure mmHg 240 230 250

Boost compensator adjustment_03

Pump speed r/min 1100 1100 1100

Rack position R1(10.4)

Boost pressure kPa 60 53.3 60

Boost pressure mmHg 450 400 450

Timer adjustment

Pump speed r/min 1300+50

Advance angle deg. 0 0 0

Remarks
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

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL (3)Boost compensator stroke: BCL
----------
T1=A84 RAL=13.2+0.2mm BCL=1.8+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=60deg+-5deg b=(35deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=12mm
----------
a=0deg+-5deg b=40deg+-5deg

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)

Information:

Table 1
Revision Summary of Changes
01 Updated Illustration 1
02 Updated effectivity Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Inadequate battery negative bonding to engine block causing incorrect diagnostic codes/tripping in the units that are disconnected from the engine-mounted charging alternator.Solution
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.
Illustration 1 g06575359
Generator set isolated DC supply system
(1) Electronic subsystem 1
(2) Electronic subsystem 2
(3) Electronic subsystem 3
(4) Generator set subsystem loads
(5) Engine ECM
(6) Starter
(7) Electronics power buss
(8) Electronics single point ground
(9) 12AWG (4 Sq.mm) bonding jumper (multi strand) wire
(10) Battery disconnect switch
(11) Customer ground connection
(12) Battery
(13) Battery charger
(14) Customer scopeNote: The red color connections in Illustration 1 are to be connected at customer site. Connections should be made after the battery disconnect switch (10).Caterpillar is aware of the problem, and is recommending the following interim solution.Install a 12AWG (4 Sq.mm) bonding jumper (multi strand) wire (9) connecting all electrical sensor grounding points (8) at the power distribution box to the customer ground connection (11). Refer to Illustration 1.Reference: Refer to Special Instruction, REHS4634, "Grounding Design Guide for Electric Power Generation Products".