101492-9463 ZEXEL F 01G 09U 0HU BOSCH INJECTION-PUMP ASSEMBLY f01g09u0hu 1014929463 16712na006

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09U 0HU f01g09u0hu

ZEXEL 101492-9463 1014929463

NISSAN-DIESEL 16712NA006 16712na006

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Include in #1:

103860-0150 as _

103860-0152

Cross reference number

BOSCH F 01G 09U 0HU f01g09u0hu

ZEXEL 101492-9463 1014929463

NISSAN-DIESEL 16712NA006 16712na006

Zexel num

Bosch num

Firm num

Name

101492-9463

F 01G 09U 0HU

16712NA006 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
BD30T15 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 3.4 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 A

Rack position 11

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 71.5 70.5 72.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.3+-0.5

Pump speed r/min 500 500 500

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.

Injection quantity adjustment_03

Adjusting point C

Rack position 11.2++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 70 80

Fixing the lever *

Rack limit *

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)Set at delivery
----------
K=16
----------

Speed control lever angle

F:Full speed I:Idle (1)Base lever only (2)Set the pump speed at aa. ( At delivery ) (3)Stopper bolt setting (4)When pump speed set at bb (5)Stopper bolt setting
----------
aa=910r/min bb=750r/min
----------
a=8deg+-5deg b=16deg+-5deg c=20deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=12deg+-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=A a2=B a3=C r1=750r/min r2=750r/min r3=750r/min Q1=- Q2=71.5+-1mm3/st Q3=- c1=- c2=+-3.5% c3=- a4=18 a5=15 a6=- r4=900r/min r5=750r/min r6=-

Timing setting

(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=8deg
----------
a=(100deg)

Information:

FACE="Courier New">CONFIDENTIAL
TECHNICAL INFORMATION BULLETIN March 27, 2002
Engines 3516 (25Z, 5SJ, 7KM, CMD, 4XF)
3516B (1HZ, 7RN, 5AN, FDN, BDP,
6HN)
Component Code: 1404SUBJECT: Generator Stator Adapter Cracking on 3516 Diesel Generator Set
PROBLEM:
Certain SR4B single bearing generators may develop cracks in the adapter assembly. The generator adapter is the welded assembly, part of the generator stator, consisting of the front adapter ring that bolts to the flywheel housing and the individual support bars welded to this adapter ring. Several different weld failure modes exist for the generator adapter. First, there may be cracks along the top weld leg between the adapter supports and the front adapter ring. Second, there may be cracks at the toe of the welds joining the adapter support bars to the front ring. These cracks appear in the heat-affected zone of the welds and propagate into the front adapter ring of the generator. The third failure mode is radial cracks between the end ring of the generator adapter and the stator housing. This type of crack most likely occurs after the support welds have failed. After the support welds have failed, the cracks at the toe of the support bars propagate into the ring and create a stress riser.
SOLUTION:
Caterpillar is redesigning the current product and is also working on a solution that will address the existing units in the field. At this time, it is NOT recommended to immediately replace cracked generator stators, nor is it recommended to re-weld the cracked adapters as a field repair. Rather, a crack observation and evaluation process should be established for each individual case. It is anticipated that the first recognizable cracks on suspect generators (cracks size of 0.25" and larger) may appear as early as 300 hours. If any of the above-described cracks are found, the servicing dealer should contact Caterpillar Service. The servicing dealer should also assist in periodic inspection of the cracks in an effort to determine the next action.
Contact (if different from sender): Miro Halicek (770) 233-5877 or Marc Sylvester (770) 233-5630.
COPYRIGHT 2002 CATERPILLAR
ALL RIGHTS RESERVED