101631-9562 ZEXEL 9 400 610 284 BOSCH INJECTION-PUMP ASSEMBLY 9400610284 1016319562 16700c6304

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 284 9400610284

ZEXEL 101631-9562 1016319562

NISSAN-DIESEL 16700C6304 16700c6304

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Service parts 101631-9562 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101063-9300

3. GOVERNOR 105542-3381

4. SUPPLY PUMP 105220-4871

5. AUTOM. ADVANCE MECHANIS 105622-0820

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:

101631-9562 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-3010 as _

104740-3011

Cross reference number

BOSCH 9 400 610 284 9400610284

ZEXEL 101631-9562 1016319562

NISSAN-DIESEL 16700C6304 16700c6304

Zexel num

Bosch num

Firm num

Name

101631-9562

9 400 610 284

16700C6304 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD33 * K 14BE 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

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

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 10.7

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 29.6 28.6 30.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.5+-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 500

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 3.6 3.1 4.1

Timer adjustment_04

Pump speed r/min 1900

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) P:Negative pressure (1)Pneumatic governor (2)Mechanical governor (3)Acting negative pressure: P1 (4)Beginning of idle sub spring operation: L1 (5)With stopper disk.
----------
L1=8+0.3mm
----------

Speed control lever angle

B:When boosted N:Normal S:Stop (1)Rack position = aa (2)Rack position bb
----------
aa=(1.8)mm bb=18mm
----------
a=18deg+-3deg b=14deg+-5deg c=4deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(140deg)

Information:

December 9, 2005
U-389
A-289
D-306
O-325
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN FUEL INJECTORS FROM DEALERS PARTS STOCK
7750 PI70111
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
March 31, 2006PROBLEM
A machining error can cause the valve body tocrack through the high-pressure line. This crack can result in fuel inthe engine oil.ACTION REQUIRED
All 10R-0957 unit injectors within serial numberrange 848368-850132 should be removed from parts stock. All 10R-0960, 10R-0961,and 10R-0963 within serial number range 188029-188914 should be removedfrom parts stock.SERVICE CLAIM ALLOWANCES
Submit one claim for all 10R0957, 10R0960, 10R0961,and 10R0963 Injectors removed from parts stock.PARTS DISPOSITION
All dealers are to make sure the outsideof the shipping container is marked PI70111.***** U.S. and Canadian Dealers *****Return all 10R0957, 10R0960, 10R0961, and 10R0963Injectors that are removed from parts stock and a copy of the claim to:Caterpillar Inc.
Attn: Supplier Recovery PI70111
Service Claims Room
8201 N. University
Peoria, IL 61615***** All Other Dealers *****Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.