101631-9860 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016319860


 

Information injection-pump assembly

ZEXEL 101631-9860 1016319860
101631-9860 INJECTION-PUMP ASSEMBLY
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Service parts 101631-9860 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101063-9370
3. GOVERNOR
4. SUPPLY PUMP 105220-4871
5. AUTOM. ADVANCE MECHANIS 105622-1100
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105141-1881
11. Nozzle and Holder 16600-20053
12. Open Pre:MPa(Kqf/cm2) 9.8{100}
13. NOZZLE-HOLDER 105071-1241
14. NOZZLE 105000-1080
15. NOZZLE SET

Include in #1:

101631-9860 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101631-9860 1016319860


Zexel num
Bosch num
Firm num
Name
101631-9860 
101631-9862 
 
  NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
SD33 *

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
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   1-4-2-6- 3-5
Pre-stroke mm   2.15 2.1 2.2
Rack position   R=11.7
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.5 60.5
Difference between angles 2
Cyl.1-2
deg.   120 119.5 120.5
Difference between angles 3
Cal 1-6
deg.   180 179.5 180.5
Difference between angles 4
Cal 1-3
deg.   240 239.5 240.5
Difference between angles 5
Cal 1-5
deg.   300 299.5 300.5
Injection quantity adjustment
Adjusting point   -
Rack position   12.2
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   32.1 31.1 33.1
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the rack   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   11.7
Pump speed r/min   1900 1900 1900
Average injection quantity mm3/st.   36.1 34.5 37.7
Max. variation between cylinders %   0 -4 4
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   -
Rack position   8.6+-0.5
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   7.5 6.5 8.5
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Timer adjustment
Pump speed r/min   550--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   500
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1100
Advance angle deg.   1.7 1.2 2.2
Timer adjustment_04
Pump speed r/min   1900
Advance angle deg.   6 5.5 6.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101631-9860
N:Pump speed R:Rack position (mm) P:Negative pressure (1)Pneumatic governor (2)Mechanical governor (3)Acting negative pressure: P1 (4)RACK LIMIT: RAL (5)Beginning of idle sub spring operation: L1 (6)Injection quantity Q = Q1 or less
----------
P1=3.63+-0.2kPa(370+-20mmAq) RAL=16.7-0.3mm L1=9+0.3mm Q1=3mm3/st
----------

Speed control lever angle

Test data 101631-9860
N:Normal B:When boosted S:Stop (1)Rack position = aa (2)Rack position corresponding to bb
----------
aa=(1.8)mm bb=18mm
----------
a=20.5deg+-3deg b=11.5deg+-5deg c=0.5deg+-5deg

Timing setting

Test data 101631-9860
(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(130deg)




Information:

Regular service intervals, along with close daily visual inspection and the adherence to the instructions and schedules, will assure many hours of trouble-free service. If correction steps are taken immediately on discovery of any abnormal condition, fewer forced stops and more economical operation will result.The Lubrication and Maintenance Chart is intended as a guide and adjustments in the schedule may be necessary, depending on conditions under which the engine is operating. A thorough analysis should be made before adjusting the maintenance schedule.Some items to consider in establishing a new schedule are: Severe dust or dirty conditions, fuel consumption (a good measurement to establish intervals as it indicates the amount of work performed). As a guideline, the 3408 Engine with a 12 gal. (45 litre) (10 imp. gal.) capacity crankcase will use approximately 4000 gal. (15,000 litre) (3332 imp. gal.) between oil changes.* The 3412 Engine with a 16 gal. (60.5 litre) (13 imp. gal.) capacity crankcase will use approximately 5100 gal. (19,200 litre) (4248 imp. gal.) between oil changes. *Reducing or extending the maintenance intervals should be done only after complete study and enough time to gain adequate experience to meet specific operations.*With 0.5% or less fuel sulphur content.Caterpillar scheduled oil sampling: Scheduled oil sampling is a program which analyzes oil samples taken from an engine at regular intervals (usually at oil change periods). This oil analysis does not indicate the condition of the oil; but rather, it is a scheduled procedure to determine engine condition at regular intervals by analyzing lubricating oil for foreign and wear particles.The scheduled oil sampling will give the following benefits:It assures the owner that maintenance has been performed.It will show the first signs of excessive wear, meaning a possible upcoming failure, allowing time for a scheduled repair.It will warm maintenance personnel of improper or lack of maintenance and presence of fuel dilution or antifreeze in oil.It is particularly helpful in preventing wear due to dirt entry from air cleaner or inlet piping.Regular sampling is especially advantageous for new engines to establish wear trends from the beginning. The results of the oil analysis are interpreted by experienced, highly trained personnel. Contact your Caterpillar dealer for detailed information.

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