101691-9910 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016919910


 

Information injection-pump assembly

ZEXEL 101691-9910 1016919910
101691-9910 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101691-9910 1016919910


Zexel num
Bosch num
Firm num
Name
101691-9910 
101691-9914 
 
  NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
NE6T *

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 101691-9910
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 101691-9910
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=26.5deg+-5deg b=42deg+-3deg

Stop lever angle

Test data 101691-9910
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 101691-9910
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

Your truck may not have the same or all of the gauges as shown in the illustrations. The illustrations shown are of typical gauges.Gauges provide a "look" inside the engine. Be sure they are in good working order. You can determine what is the "normal" operating range by observing your gauges over a period of time.Noticeable changes in gauge readings are indicative of potential gauge or engine problems. This also applies to gauge readings that have changed significantly but are still within specifications. The cause of any sudden or significant change in the readings should be determined and corrected. Contact your Caterpillar dealer for assistance as needed. Oil Pressure - Indicates engine oil pressure. The oil pressure should be between 30 and 45 psi (207 and 310 kPa) when the engine is running at rated engine speed, with SAE 15W-40 oil, at 230°F (110°C) operating temperature. A lower pressureis normal at low idling speed.The "Check Engine" light will come on and a fault logged in the 3176 ECM system if oil pressure drops below 5 psi (35 kPa) at low idle rpm.
If no oil pressure is indicated, stop the engine. Engine damage can result.
Water Temperature - Indicates engine coolant temperature. It should normally indicate between 189°F (87°C) and 208°F (98°C). Maximum allowable temperature is 216°F (102°C) with the cooling system pressurized. Somewhat higher temperatures may occur under certain conditions. Ammeter - Indicates the amount of charge or discharge in the battery charging circuit. Normal operation of the indicator should be slightly to the positive (right) side of "0" (zero).With the engine running, during normal operation, if the indicator is constantly to the negative (left) side of "0" (zero) or shows excessive charge, have the charging system checked for malfunction. Tachometer - Indicates engine rpm (speed). The engine can be operated at high idle without damage, but should not be allowed to overspeed. Overspeeding when downshifting, going downhill, etc., can result in serious damage to your engine.
Do not exceed 2300 rpm in any situation.
Fuel Level - Indicates fuel level in the fuel tank. Electrically operated, it registers only when the key switch is ON. Fuel Pressure - Indicates fuel pressure to the unit injectors. The indicator should register in the NORMAL (green) range.Normal fuel pressure at low idle is 60 psi (410 kPa).Normal fuel pressure at TEL (Top Engine Limit) is 80 psi (550 kPa).
Never operate the 3176 Engine with the fuel pressure below 65 psi (450 kPa) at rated speed. Engine damage could result.
The "Check Engine" light will come on and a fault logged in the 3176 ECM system if fuel pressure drops below 65 psi (450 kPa) at rated speed (rpm).A drop in fuel pressure usually indicates a dirty or plugged fuel filter. Service Hour Meter - Indicates the total number of clock hours the engine has operated.

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