101691-9903 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016919903


 

Information injection-pump assembly

ZEXEL 101691-9903 1016919903
101691-9903 INJECTION-PUMP ASSEMBLY
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Service parts 101691-9903 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101069-3650
3. GOVERNOR 105921-2353
4. SUPPLY PUMP 105220-5690
5. AUTOM. ADVANCE MECHANIS 105614-3311
6. COUPLING PLATE 105661-0631
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-5620
11. Nozzle and Holder 16600-95015
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105031-4620
14. NOZZLE 105015-7360
15. NOZZLE SET

Include in #1:

101691-9903 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101691-9903 1016919903


Zexel num
Bosch num
Firm num
Name
101691-9903 
 
   
INJECTION-PUMP ASSEMBLY

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 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   1-4-2-6- 3-5
Pre-stroke mm   3.7 3.65 3.75
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   13.7
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   109 107.4 110.6
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   9.8+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   9 7.2 10.8
Max. variation between cylinders %   0 -10 10
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(13.7)
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   109 108 110
Basic   *
Fixing the lever   *
Boost pressure kPa   30.7 30.7
Boost pressure mmHg   230 230
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   101.4 99.4 103.4
Fixing the lever   *
Boost pressure kPa   30.7 30.7
Boost pressure mmHg   230 230
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(12.6)
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   61.6 59.6 63.6
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   85 85 105
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   R3(12)
Boost pressure kPa   4 2.7 5.3
Boost pressure mmHg   30 20 40
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   R3+0.4
Boost pressure kPa   9.3 8 10.6
Boost pressure mmHg   70 60 80
Boost compensator adjustment_03
Pump speed r/min   600 600 600
Rack position   R1-0.6
Boost pressure kPa   17.3 17.3 17.3
Boost pressure mmHg   130 130 130
Timer adjustment
Pump speed r/min   920--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   870
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101691-9903
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B36 BCL=(1.1)+-0.1mm
----------

Speed control lever angle

Test data 101691-9903
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=100mm
----------
a=26.5deg+-5deg b=42deg+-3deg

Stop lever angle

Test data 101691-9903
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=36mm
----------
a=20deg+-5deg b=40deg+-5deg

Timing setting

Test data 101691-9903
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)




Information:

Fluid Penetration
Always use a board or cardboard when checking for a leak. Escaping fluid under pressure, even a pin-hole size leak, can penetrate body tissue, causing serious injury, and possible death.If fluid is injected into your skin, it must be treated by a doctor familiar with this type of injury immediately.Asbestos Information
Caution should be used to avoid breathing dust that may be generated when handling components containing asbestos fibers. If this dust is inhaled, it can be hazardous to your health.Components in Caterpillar products that may contain asbestos fibers are brake pads, brake band and lining assemblies, clutch plates and some gaskets.The asbestos used in these components is usually bound in a resin or sealed in some way. Normal handling is not hazardous as long as airborne dust which contains asbestos is not generated.If dust which may contain asbestos is present, there are several common sense guidelines that should be followed.* Never use compressed air for cleaning.* Avoid brushing or grinding of asbestos containing materials.* For clean up, use wet methods or a vacuum equipped with a high efficiency particulate air (HEPA) filter.* Use exhaust ventilation on permanent machining jobs.* Wear an approved respirator if there is no other way to control the dust.* Comply with applicable rules and regulations for the work place (for example in the U.S.A., OSHA requirements as set forth in 29 CFR 1910.1001).* Follow environmental rules and regulations for disposal of asbestos.* Avoid areas where asbestos particles may be in the air.Lines, Tubes and Hoses
Do not bend or strike high pressure lines. Do not install bent or damaged lines, tubes or hoses.Repair any loose or damaged fuel and oil lines, tubes and hoses. Leaks can cause fires.Inspect all lines, tubes and hoses carefully. Do not use your bare hands to check for leaks. Tighten all connections to the recommend torque.* End fittings damaged or leaking.* Outer covering chafed or cut and wire reinforcing exposed.* Outer covering ballooning locally.* Evidence of kinking or crushing of the flexible part of the hose.* Armoring embedded in the outer cover.* End fittings displaced.Burn Prevention
Do not touch any part of an operating engine. Allow the engine to cool before any repairs are performed on the engine.Relieve all pressure in air, oil, fuel or cooling systems before any lines, fittings or related items are disconnected or removed.Coolant
To prevent personal injury, do not step up on engine to remove the filler cap, if applicable. Use an adequate ladder.At operating temperature, the engine coolant is hot and under pressure. The radiator and all lines to heaters or the engine contain hot water. When pressure is relieved rapidly, this hot water can turn into steam.Any contact with hot water or steam can cause severe burns.Check the coolant level only after the engine has been stoped and the filler cap is cool enough to remove with your bare hand.Remove the cooling system filler cap slowly to relieve pressure.Supplemental cooling system additive contains alkali. To prevent personal injury, avoid contact with the skin and

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