Information injection-pump assembly
ZEXEL
101631-9830
1016319830
NISSAN-DIESEL
1679090205
1679090205

Rating:
Service parts 101631-9830 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-90019
12.
Open Pre:MPa(Kqf/cm2)
9.8{100}
15.
NOZZLE SET
Include in #1:
101631-9830
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-3460
as _
Cross reference number
ZEXEL
101631-9830
1016319830
NISSAN-DIESEL
1679090205
1679090205
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
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
2.3
2.25
2.35
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
14.5
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
34.2
33.2
35.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
13.8
Pump speed
r/min
1550
1550
1550
Average injection quantity
mm3/st.
35
33.5
36.5
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
-
Rack position
10.6+-0.
5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
7.5
6.4
8.6
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
500+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
1
0.5
1.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
2.8
2
3.5
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
5
4.5
5.5
Timer adjustment_05
Pump speed
r/min
1600
Advance angle
deg.
5.8
5.3
6.3
Timer adjustment_06
Pump speed
r/min
-
Advance angle
deg.
7.5
7.5
7.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
----------
K=15
----------
----------
K=15
----------
Speed control lever angle

F:Full speed
I:Idle
S:Stop
----------
----------
a=28deg+-5deg b=43deg+-5deg c=32deg+-3deg
----------
----------
a=28deg+-5deg b=43deg+-5deg c=32deg+-3deg
Stop lever angle

N:Pump normal
S:Stop the pump.
----------
----------
a=19deg+-5deg b=53deg+-5deg
----------
----------
a=19deg+-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:Maximum no-load speed (r/min)
LABEL9:Remarks
(1)Adjustment conditions are the same as those for measuring injection quantity.
(2)At high idle rack position L
----------
L=9mm
----------
a1=A a2=B a3=C a4=D a5=- a6=- r1=800r/min r2=750r/min r3=600r/min r4=600r/min r5=- r6=- Q1=37.6+-1mm3/st Q2=35.2+-1mm3/st Q3=34.2+-1mm3/st Q4=27.1+-1mm3/st Q5=- Q6=- c1=+-2.5% c2=+-2.5% c3=+-2.5% c4=+-2.5% c5=- c6=- a7=32 a8=31 a9=30 a10=29 a11=28 a12=27 a13=26 a14=25 a15=24 a16=23 a17=22 a18=21 a19=20 a20=19 a21=18 a22=17 a23=16 a24=15 a25=- a26=- a27=- a28=- r7=1600r/min r8=1550r/min r9=1500r/min r10=1450r/min r11=1400r/min r12=1350r/min r13=1300r/min r14=1250r/min r15=1200r/min r16=1150r/min r17=1100r/min r18=1050r/min r19=1000r/min r20=950r/min r21=900r/min r22=850r/min r23=800r/min r24=750r/min r25=- r26=- r27=- r28=- R7=1720+-40r/min R8=1665+-38r/min R9=1610+-37r/min R10=1555+-36r/min R11=1505+-35r/min R12=1450+-33r/min R13=1395+-32r/min R14=1340+-31r/min R15=1290+-30r/min R16=1235+-28r/min R17=1180+-27r/min R18=1130+-26r/min R19=1075+-25r/min R20=1020+-23r/min R21=965+-22r/min R22=915+-22r/min R23=860+-20r/min R24=805+-18r/min R25=- R26=- R27=- R28=-
----------
L=9mm
----------
a1=A a2=B a3=C a4=D a5=- a6=- r1=800r/min r2=750r/min r3=600r/min r4=600r/min r5=- r6=- Q1=37.6+-1mm3/st Q2=35.2+-1mm3/st Q3=34.2+-1mm3/st Q4=27.1+-1mm3/st Q5=- Q6=- c1=+-2.5% c2=+-2.5% c3=+-2.5% c4=+-2.5% c5=- c6=- a7=32 a8=31 a9=30 a10=29 a11=28 a12=27 a13=26 a14=25 a15=24 a16=23 a17=22 a18=21 a19=20 a20=19 a21=18 a22=17 a23=16 a24=15 a25=- a26=- a27=- a28=- r7=1600r/min r8=1550r/min r9=1500r/min r10=1450r/min r11=1400r/min r12=1350r/min r13=1300r/min r14=1250r/min r15=1200r/min r16=1150r/min r17=1100r/min r18=1050r/min r19=1000r/min r20=950r/min r21=900r/min r22=850r/min r23=800r/min r24=750r/min r25=- r26=- r27=- r28=- R7=1720+-40r/min R8=1665+-38r/min R9=1610+-37r/min R10=1555+-36r/min R11=1505+-35r/min R12=1450+-33r/min R13=1395+-32r/min R14=1340+-31r/min R15=1290+-30r/min R16=1235+-28r/min R17=1180+-27r/min R18=1130+-26r/min R19=1075+-25r/min R20=1020+-23r/min R21=965+-22r/min R22=915+-22r/min R23=860+-20r/min R24=805+-18r/min R25=- R26=- R27=- R28=-
Timing setting

(1)Pump vertical direction
(2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(130deg)
----------
----------
a=(130deg)
Information:
Spray starting fluid only while cranking the engine.
1. Heat the glow plugs (If equipped) for the approximate heating time shown in the STARTING AID CHART. 2. Turn the HEAT-START switch to START position. While cranking, spray starting fluid into the air inlet or air cleaner for approximately 1 second.
Wait at least 2 seconds before spraying starting fluid again.
3. If necessary, repeat the procedure.4. After the engine starts, it may be necessary to return the HEAT-START switch to the HEAT position until the engine runs smoothly.Jacket Water Heater (Attachment)
In very low temperatures, the lubricating oil must be warmed to allow starting. A jacket water heater can maintain the water temperature at approximately 90°F (32°C). The warm water will keep the oil in the upper part of the engine block warm enough to flow when starting.Dipstick Oil Heater
Contact your Caterpillar dealer before installing a dipstick crankcase oil heater.
Generator
Starting Single Unit Operation
1. Make all preliminary engine starting checks.2. Be sure the main or line circuit breaker is open.3. Start the engine and allow it to warm up.4. Close the main circuit breaker.5. Apply the load. Do not try to apply full load in one move, rather apply the load in increments to maintain system frequency at a constant level.Standby Generator Sets
Most standby units are automatic. They start, pickup the load, run and stop without an operator in attendance. Standby units can not change the governor control setting automatically. The throttle must be preset for the proper operation of that unit. Whenever the set is exercised or operated manually, be sure the throttle setting is correct for automatic operation. Check all switches to see they are properly set: Start Selector Switch in AUTOMATIC position and any Emergency Stop Switches in RUN position.Paralleling
Units may be paralleled at no load or paralleled with units under load. To parallel two or more units the following conditions must be met:1. Same phase rotation.2. Same voltage level.3. Same voltage droop.4. Same frequency.5. Voltages must be in phase.The first condition is established by "phased" wiring connections of initial installation.The second and third conditions are usually established by semi-permanent adjustments to the generator controls.The fourth and fifth conditions are under control of the operation in manual paralleling systems (or under automatic control in automatic paralleling systems).To Parallel
1. Start the unit to be paralleled.2. Turn the synchronizer lights on.3. After the engine has run long enough to warm up, bring it up to synchronous speed (the same frequency as the unit on the line). The synchronizing lights will begin to blink.4. Using the governor control, adjust the speed until the lights blink very slowly.5. The lights are off when the voltages of the two units are in phase. At this point, very quickly close the breaker while the lights are out. The frequency of the incoming unit should be slightly greater than the line frequency. This will allow the incoming unit to assume some of the load rather than add to the system load.Load Division
Once two units have been paralleled,