101482-9190 ZEXEL 9 400 614 261 BOSCH INJECTION-PUMP ASSEMBLY 9400614261 1014829190 1679090360

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 261 9400614261

ZEXEL 101482-9190 1014829190

NISSAN-DIESEL 1679090360 1679090360

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Service parts 101482-9190 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101048-8160

3. GOVERNOR 105419-0440

4. SUPPLY PUMP 105220-5740

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-6020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5780

11. Nozzle and Holder 1660090074

12. Open Pre:MPa(Kqf/cm2) 15.7(160)

13. NOZZLE-HOLDER 105048-3390

14. NOZZLE

105017-0900

15. NOZZLE SET

Include in #1:

101482-9190 as INJECTION-PUMP ASSEMBLY

Include in #2:

105856-3020 as _

Cross reference number

BOSCH 9 400 614 261 9400614261

ZEXEL 101482-9190 1014829190

NISSAN-DIESEL 1679090360 1679090360

Zexel num

Bosch num

Firm num

Name

101482-9190

9 400 614 261

1679090360 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
BD30 * 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 131424-1520

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 3.2 3.15 3.25

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 10.3

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 42.2 41.2 43.2

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 61 61 71

Fixing the lever *

Rack limit *

Injection quantity adjustment_03

Adjusting point -

Rack position 9.2+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 8 6 10

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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

Test data Ex:

Governor adjustment

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 between N = N1 and N = N2
----------
K=15 N1=1150r/min N2=800r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=20deg+-5deg b=9deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

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

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(100deg)

Information:

ACTION REQUIRED
Flash engine ECM with new 422-8397 Software on machines located in North America.
Flash engine ECM with new 422-8398 Software on machines located in Europe.
Refer to Special Instruction, REHS7927 for instructions on replacing the diesel particulate filter pressure lines group.
Refer to Special Instruction, REHS7197 for instructions on installing the engine cooling fan bypass feature.
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*******
0-5000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 12.0-hour job for Group 1
Travel and mileage will be allowed under this program
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-5000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 12.0-hour job for Group 2
Travel and mileage will be allowed under this program
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.