101631-9590 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016319590 1671790061

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101631-9590 1016319590

NISSAN-DIESEL 1671790061 1671790061

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Service parts 101631-9590 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101063-9290

3. GOVERNOR 105410-4310

4. SUPPLY PUMP 105220-4630

5. AUTOM. ADVANCE MECHANIS 105622-0250

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105071-1241

14. NOZZLE

105000-1010

15. NOZZLE SET

Include in #1:

101631-9590 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-3050 as _

104740-3060

Cross reference number

ZEXEL 101631-9590 1016319590

NISSAN-DIESEL 1671790061 1671790061

Zexel num

Bosch num

Firm num

Name

101631-9590

1671790061 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 2.3 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 A

Rack position 14

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 32 31 33

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 11.8

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 19.5 18 21

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 10.8

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 7.5 6.4 8.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 500+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 1 0.5 1.5

Timer adjustment_03

Pump speed r/min (895)

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

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)Target notch: K
----------
K=13
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Speed set at aa (setting at shipping) (2)Set the pump speed at bb.
----------
aa=900r/min bb=750r/min
----------
a=10deg+-5deg b=27deg+-5deg c=32deg+-3deg d=7.5deg+-5deg

Stop lever angle

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

----------
a=(19deg) b=(47deg)

Timing setting

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

----------
a=(130deg)

Information:

20Oct2015
U-557
A-401
D-483
O-483
TM-15
TA-4
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING CERTAIN 20R-0476 INJECTOR ASSEMBLIES FROM DEALER PARTS STOCK
7750 PI70592
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
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.
TERMINATION DATE
31Jan2016
PROBLEM
All 20R-0476 Injector Assemblies in dealer parts stock need to be inspected for the date code. 20R-0476 Injector Assemblies that have a date code of D08M07Y15P47 need to be removed from dealer parts stock. These injector as may have a nozzle assembly marked 2645K015 which is not correct. (Image1 = Incorrect) The correct nozzle assembly should be marked 2645K016. (Image2 = Correct) These two nozzles are not interchangeable.
ACTION REQUIRED
Inspect the date code on all 20R-0476 Injector Assemblies in dealer parts stock. 20R-0476 Injector Assemblies that have a date code of D08M07Y15P47 need to be removed from dealer parts stock.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.