101641-9281 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016419281 16700l9001

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101641-9281 1016419281

NISSAN-DIESEL 16700L9001 16700l9001

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Cross reference number

ZEXEL 101641-9281 1016419281

NISSAN-DIESEL 16700L9001 16700l9001

Zexel num

Bosch num

Firm num

Name

101641-9281

16700L9001 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD33T * 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

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 2.3 2.25 2.35

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 13.5

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 47.3 46.2 48.4

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.9+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 9.2 8.1 10.3

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.5)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 47.3 46.3 48.3

Basic *

Fixing the lever *

Boost pressure kPa 51.3 51.3

Boost pressure mmHg 385 385

Injection quantity adjustment_04

Adjusting point B

Rack position R1(13.5)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 48.7 44.7 52.7

Fixing the lever *

Boost pressure kPa 51.3 51.3

Boost pressure mmHg 385 385

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.8

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 36.2 32.2 40.2

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R1-0.8

Boost pressure kPa 19.3 19.3 19.3

Boost pressure mmHg 145 145 145

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R1-0.5

Boost pressure kPa 26 24.7 27.3

Boost pressure mmHg 195 185 205

Boost compensator adjustment_03

Pump speed r/min 400 400 400

Rack position R1(13.5)

Boost pressure kPa 38 38 38

Boost pressure mmHg 285 285 285

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 700

Advance angle deg. 1

Timer adjustment_04

Pump speed r/min 1050

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 7.5 7.5 7.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=89 RAL=13.8+0.2mm
----------

Speed control lever angle

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

----------
a=0deg+-5deg b=37deg+-3deg

Stop lever angle

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

----------
a=20deg+-5deg b=40deg+-5deg

0000001501 RACK SENSOR

V1:Supply voltage Vf:Full side output voltage Vi:Idle side output voltage (a) Speed lever (B) Link (c) Nut (F) Full (I) Idle (P) Potentiometer 1. Load sensor adjustment (1)Apply DC5 = V1 voltage between potentiometer connector terminals (1) ~ (3) and measure the output voltage between (1) ~ (2). (2)Move the speed lever (A) until it contacts the full side stopper bolt and then turn the link (B) to adjust the potentiometer (P)'s output voltage to Vf. (3)Confirm that the speed lever (A) turns smoothly between idle (I) and Full (F) and tighten the nut (C). (Tightening torque: 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m}) (4)Move the speed lever (A) several times between idle (I) and full (F) and confirm that the voltage is Vf when it contacts the full side stopper bolt and Vi when it contacts the idle side stopper bolt.
----------
V1=5+-0.02V Vf=4.8++V Vi=0.5+0.4-0.3V
----------

Timing setting

(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:

Torque for Standard Bolts, Nuts and Taperlock Studs
The following charts give general torques for bolts, nuts, and taperlock studs. For torque specifications not included in this section, refer to Torque Specifications, SENR3130, available from your Caterpillar dealer.
Torques for Bolts and Nuts With Standard Threads
Torques for Taperlock Studs
Use these standard torque values for all fasteners, unless otherwise specified in this manual or in the Service Manual.Torque for Metric Fasteners
Be very careful never to mix metric with customary (SAE standard) fasteners. Mismatched or incorrect fasteners will cause engine damage or malfunction and may even result in personal injury.Original fasteners removed from the engine should be saved for reassembly whenever possible. If new fasteners are needed, they must be of the same size and grade as the ones that are being replaced.
Material strength identification is usually shown on the bolt head by numbers (8.8, 10.9, etc.). The following chart gives general torque values for bolts and nuts. Use these standard torque values unless otherwise specified in this publication. Metric hardware must be replaced with metric hardware. Check Parts Manual for proper replacement.Torques for Bolts and Nuts with Metric Threads
Torque for Standard Hose Clamps-Worm Drive Band Type
The following chart gives the torques for initial installation of hose clamps on new hose and for reassembly or tightening of hose clamps on existing hose. Torque for Constant Torque Hose Clamps
Due to extreme temperature changes, hose will heat set. Heat settings causes hose clamps to loosen. Loose hose clamps can result in leaks. There have been reports of component failures caused by hose clamps loosening. The new constant torque hose clamp will help prevent these failures. A constant torque hose clamp can be used in place of any standard hose clamp. Make sure the constant torque hose clamp is the same size as the standard clamp.
Installation
Each installation application can be different depending on the type of hose, fitting material, and anticipated expansion or contraction of the hose and fittings. A torque wrench should be used for proper installation of constant torque hose clamps. Constant torque hose clamps should be installed as follows:* To allow for maximum expansion, install clamps at 5.7 N m (50 lb in).* To allow for equal expansion and contraction, install clamps at 10.2 N m (90 lb in).* To allow for maximum contraction, install clamps at 14.1 N m (125 lb in).