101602-9561 ZEXEL 9 400 614 977 BOSCH INJECTION-PUMP ASSEMBLY 9400614977 1016029561 16712z5504

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 977 9400614977

ZEXEL 101602-9561 1016029561

NISSAN-DIESEL 16712Z5504 16712z5504

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Service parts 101602-9561 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3650

3. GOVERNOR 105400-3281

4. SUPPLY PUMP 105220-5640

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-0391

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5511

11. Nozzle and Holder 16600-Z5511

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105031-4520

14. NOZZLE 105015-5170

15. NOZZLE SET

Include in #1:

101602-9561 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-6592 as _

Cross reference number

BOSCH 9 400 614 977 9400614977

ZEXEL 101602-9561 1016029561

NISSAN-DIESEL 16712Z5504 16712z5504

Zexel num

Bosch num

Firm num

Name

101602-9561

9 400 614 977

16712Z5504 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD6 K 14BE INJECTION PUMP ASSY PE6A PE

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 2.95 3.05

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 A

Rack position 9

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 44.7 43.1 46.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.4

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 37.5 35.9 39.1

Max. variation between cylinders % 0 -3 3

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8.2 6.4 10

Max. variation between cylinders % 0 -12 12

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Rack difference between N = N1 and N = N2
----------
K=15 N1=900r/min N2=400r/min
----------

Speed control lever angle

F:Full speed I:Idle M:Minimum-maximum speed (1)Set the pump speed at aa. (At delivery) (2)Stopper bolt setting (3)Pump speed = bb
----------
aa=900r/min bb=750r/min
----------
a=8deg+-5deg b=21deg+-5deg c=5deg+-5deg

Stop lever angle

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

----------
a=26.5deg+-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:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)-
----------

----------
a1=A a2=B r1=750r/min r2=750r/min Q1=48.2+-1.6mm3/st Q2=44.7+-1.6mm3/st c1=+-2% c2=+-2% a3=18 a4=15 r3=900r/min r4=750r/min

Timing setting

(1)Pump vertical direction (2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

Caterpillar: Confidential Yellow
PSP FOR INSTALLING NEW FUEL INJECTION LINE BRACKETS AND CLAMPS ON CERTAIN D8L TRACTORS, D9N TRACTORS, 589 PIPELAYERS, 631E SCR APERS, 637E SCRAPERS, 657E SCRAPERS, 768C TRACTORS, 769C TRUCKS, 834B TRACTORS, AND 988B LOADERS - PS4428 - MAILED US AND CA NADA, CACO, COFA, BRAZIL, CFEL, COSA
The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
U-63 A-35 AU-38 B-13 E-39 O-54 1252 PS4428 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4428" as Part Number, "7755" as Group Number, and "96" as Description Code. Termination Date
March 31, 1991
Problem
The fuel lines on certain D8L Tractors, D9N Tractors, 589 Pipelayers, 631E Scrapers, 637E Scrapers, 657E Scrapers, 768C Tractors, 769C Trucks, 834B Tractors, and 988B Loaders may fail. New brackets and clamps can be installed to increase the service life of the fuel injection lines.
Affected Product
Model Identification Number D8L 7YB962 7JC778 D9N 1JD1288, 1295, 1296, 1298-1356, 1358, 1361-2039, 2045, 2048, 2049, 2052 589 31Z423-452 631E 1AB965-1198, 1209 637E 1FB361-416, 418, 422 1JB612-724 657E