101491-9180 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919180

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-9180 1014919180

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Cross reference number

ZEXEL 101491-9180 1014919180

Zexel num

Bosch num

Firm num

Name

101491-9180
101491-9183

NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD33 *

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 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 3.4 3.35 3.45

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 9.5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 44.3 42.3 46.3

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 8.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8.2 6.2 10.2

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 44.3 43.3 45.3

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 53 49 57

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.1

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 40.1 36.1 44.1

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.7

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 36.7 32.7 40.7

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 69 69 79

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 1.75 1.25 2.25

Timer adjustment_04

Pump speed r/min 1800

Advance angle deg. 3.5 3 4

Timer adjustment_05

Pump speed r/min 1850

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 (3)Torque cam set point
----------
T1=A54
----------

Speed control lever angle

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

----------
a=25deg+-5deg b=39deg+-3deg

Stop lever angle

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

----------
a=7deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear mark 'N') at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(60deg)

Information:

December 9, 2005
U-389
A-289
D-306
O-325
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN FUEL INJECTORS FROM DEALERS PARTS STOCK
7750 PI70111
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
March 31, 2006PROBLEM
A machining error can cause the valve body tocrack through the high-pressure line. This crack can result in fuel inthe engine oil.ACTION REQUIRED
All 10R-0957 unit injectors within serial numberrange 848368-850132 should be removed from parts stock. All 10R-0960, 10R-0961,and 10R-0963 within serial number range 188029-188914 should be removedfrom parts stock.SERVICE CLAIM ALLOWANCES
Submit one claim for all 10R0957, 10R0960, 10R0961,and 10R0963 Injectors removed from parts stock.PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked PI70111.***** U.S. and Canadian Dealers *****Return all 10R0957, 10R0960, 10R0961, and 10R0963Injectors that are removed from parts stock and a copy of the claim to:Caterpillar Inc.
Attn: Supplier Recovery PI70111
Service Claims Room
8201 N. University
Peoria, IL 61615***** All Other Dealers *****Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.