Information injection-pump assembly
ZEXEL
101605-9340
1016059340
NISSAN-DIESEL
1679095065
1679095065

Rating:
Service parts 101605-9340 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-95011
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101605-9340
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-1460
as _
Cross reference number
ZEXEL
101605-9340
1016059340
NISSAN-DIESEL
1679095065
1679095065
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
2.75
2.7
2.8
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.6
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
101.5
100
103
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
65.3
65.3
Boost pressure
mmHg
490
490
Injection quantity adjustment_02
Adjusting point
C
Rack position
R1(9.9)
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
82.5
80.5
84.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
6.4+-0.5
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
10.5
9
12
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R1(9.9)
Boost pressure
kPa
20
17.3
22.7
Boost pressure
mmHg
150
130
170
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
10.6
Boost pressure
kPa
52
45.3
58.7
Boost pressure
mmHg
390
340
440
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)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure)
(4)Boost compensator stroke: BCL
(5)Set idle sub-spring
(6)Main spring setting
----------
K=10 L1=11.5+-0.2mm BCL=(0.7)+-0.1mm
----------
----------
K=10 L1=11.5+-0.2mm BCL=(0.7)+-0.1mm
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=3deg+-5deg b=18deg+-5deg
----------
----------
a=3deg+-5deg b=18deg+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
0000001101

N:Normal
B:When boosted
(1)Rack position = aa at boost pressure 0.
----------
aa=11.5+-0.2mm
----------
a=(15deg) b=(8deg)
----------
aa=11.5+-0.2mm
----------
a=(15deg) b=(8deg)
Timing setting

(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=16deg
----------
a=(30deg)
----------
aa=16deg
----------
a=(30deg)
Information:
Fuel Recommendations
Caterpillar Diesel Engines are capable of burning a wide range of distillate fuels. The use of clean, stable blends of distillate fuel which meet the following requirements will provide quality engine service life. The fuels recommended for use in Caterpillar engines are normally No. 2-D diesel fuel and No. 2 fuel oil, although No. 1 grades are acceptable. The following fuel specifications are some of the worldwide fuels which also meet the requirements. The following fuel characteristics should be considered when procuring fuel for use in Caterpillar diesel engines.Cetane Number
The minimum cetane number required for average starting conditions for the direct injection engine is 40. A higher cetane value may be required for high altitude operation or cold weather starting.Filterability
Clean fuels should have no more than 0.1% of sediment and water. Storage of fuel for extended periods of time can cause fuel oxidation with solids forming, causing filtering problems.Pour Point
The pour point of the fuel should be at least 6°C (10°F) below the lowest ambient temperature at which the engines must start and operate. The lower pour point of No. 1 or No. 1-D fuel may be necessary in extremely cold weather.Cloud Point
The cloud point should be below the lowest ambient temperature at which the engines must start and operate to prevent the fuel filter elements from plugging with wax crystals. Refer to topic, Fuel Problems in Cold Weather Operation, for additional information.Sulfur
Fuels containing 0.5% or less sulfur may be used with normal crankcase oil drain intervals using API CD or CE performance oils. With sulfur above the 0.5% level, use API CD or CE oils with an ASTM D-2896 Total Base Number (TBN) of 20 times the fuel sulfur for normal oil drain intervals. Regular oil analysis (S*O*S) will provide information to monitor oil properties and engine wear metals to maintain successful engine protection and establish oil drain intervals.Viscosity
The viscosity of any fluid is a measure of resistance to flow. Fuel viscosity is important because it provides lubrication for fuel system components and also its effects on fuel atomization. The viscosity limits have been provided to meet both of these effects.Additives
Fuel additives are generally not recommended nor needed for the specified fuels listed. Cetane improvers can be used as necessary for the direct injection engine requirements. Biocides may be needed to eliminate microorganism growth in storage tanks. In cold conditions, treatment for entrained water may also be necessary.Consult your fuel supplier about the use of additives to prevent incompatibility among additives already in the fuel and the additives to be used. Other fuel types may be burned in the engine when economics or fuel availability dictate. Consult your Caterpillar dealer for more information and advice on any specific fuel.Fuel Sulfur Content
The percentage of sulfur in the fuel will affect the engine oil recommendations. Fuel sulfur is chemically changed during combustion to form both sulfurous and sulfuric acid. These acids chemically attack metal surfaces and cause corrosive wear.Certain additives used in lubricating oils contain alkaline compounds that
Caterpillar Diesel Engines are capable of burning a wide range of distillate fuels. The use of clean, stable blends of distillate fuel which meet the following requirements will provide quality engine service life. The fuels recommended for use in Caterpillar engines are normally No. 2-D diesel fuel and No. 2 fuel oil, although No. 1 grades are acceptable. The following fuel specifications are some of the worldwide fuels which also meet the requirements. The following fuel characteristics should be considered when procuring fuel for use in Caterpillar diesel engines.Cetane Number
The minimum cetane number required for average starting conditions for the direct injection engine is 40. A higher cetane value may be required for high altitude operation or cold weather starting.Filterability
Clean fuels should have no more than 0.1% of sediment and water. Storage of fuel for extended periods of time can cause fuel oxidation with solids forming, causing filtering problems.Pour Point
The pour point of the fuel should be at least 6°C (10°F) below the lowest ambient temperature at which the engines must start and operate. The lower pour point of No. 1 or No. 1-D fuel may be necessary in extremely cold weather.Cloud Point
The cloud point should be below the lowest ambient temperature at which the engines must start and operate to prevent the fuel filter elements from plugging with wax crystals. Refer to topic, Fuel Problems in Cold Weather Operation, for additional information.Sulfur
Fuels containing 0.5% or less sulfur may be used with normal crankcase oil drain intervals using API CD or CE performance oils. With sulfur above the 0.5% level, use API CD or CE oils with an ASTM D-2896 Total Base Number (TBN) of 20 times the fuel sulfur for normal oil drain intervals. Regular oil analysis (S*O*S) will provide information to monitor oil properties and engine wear metals to maintain successful engine protection and establish oil drain intervals.Viscosity
The viscosity of any fluid is a measure of resistance to flow. Fuel viscosity is important because it provides lubrication for fuel system components and also its effects on fuel atomization. The viscosity limits have been provided to meet both of these effects.Additives
Fuel additives are generally not recommended nor needed for the specified fuels listed. Cetane improvers can be used as necessary for the direct injection engine requirements. Biocides may be needed to eliminate microorganism growth in storage tanks. In cold conditions, treatment for entrained water may also be necessary.Consult your fuel supplier about the use of additives to prevent incompatibility among additives already in the fuel and the additives to be used. Other fuel types may be burned in the engine when economics or fuel availability dictate. Consult your Caterpillar dealer for more information and advice on any specific fuel.Fuel Sulfur Content
The percentage of sulfur in the fuel will affect the engine oil recommendations. Fuel sulfur is chemically changed during combustion to form both sulfurous and sulfuric acid. These acids chemically attack metal surfaces and cause corrosive wear.Certain additives used in lubricating oils contain alkaline compounds that