101631-9775 ZEXEL 9 400 610 068 BOSCH INJECTION-PUMP ASSEMBLY 9400610068 1016319775 16700c8605

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 068 9400610068

ZEXEL 101631-9775 1016319775

NISSAN-DIESEL 16700C8605 16700c8605

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Service parts 101631-9775 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101063-9371

3. GOVERNOR 105542-4271

4. SUPPLY PUMP 105220-4871

5. AUTOM. ADVANCE MECHANIS 105622-1100

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-2130

11. Nozzle and Holder 16600-36W00

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

13. NOZZLE-HOLDER 105071-1271

14. NOZZLE

105000-1740

15. NOZZLE SET

Include in #1:

101631-9775 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-3340 as _

Cross reference number

BOSCH 9 400 610 068 9400610068

ZEXEL 101631-9775 1016319775

NISSAN-DIESEL 16700C8605 16700c8605

Zexel num

Bosch num

Firm num

Name

101631-9775

9 400 610 068

16700C8605 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 15780-8140

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 1.95 2.05

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 -

Rack position 12.6

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 34 33 35

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 12.3

Pump speed r/min 1900 1900 1900

Average injection quantity mm3/st. 38.1 34.9 41.3

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point -

Rack position 8.6+-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 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_04

Pump speed r/min 1900

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

P:Negative pressure N:Pump speed R:Rack position (mm) (1)Pneumatic governor (2)RACK LIMIT: RAL (3)Beginning of idle sub spring operation: L1 (4)Mechanical governor (5)Acting negative pressure: P1
----------
RAL=15+-0.1mm L1=9+0.3mm P1=3.63+-0.2kPa{370+-20mmAq}
----------

0000001101

N:Normal B:When boosted S:Stop (1)Rack position = aa (2)Rack position corresponding to cc
----------
aa=0mm bb=15mm
----------
a=25deg+-3deg b=4.5deg+-5deg c=0deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(130deg)

Information:

When reporting the repair, use "PS61391" as the Part Number and "7777" as the Group Number. Use "96" as Warranty Claim Description Code and use "Z" as the SIMS 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
30Jun2020
PROBLEM
The 398-1498 and 463-1678 Fuel Injection Pumps may fail on certain 320D 2 Excavators, equipped with C7.1M Engine. The fuel injection pump failure results in the engine not starting, hard to start, low power, or speed instability.
AFFECTED PRODUCT
Model Identification Number
320D 2 LCA01054-01108
TDZ00816-00829, 888-907, 911-923
PARTS NEEDED
Qty
Part Number Description
3 2323149 WASHER-SEALING
1 4631678 PUMP AS-F INJ
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Refer REHS3767, Special Instruction, "Inspection of Fuel Injection Pumps on 3054C, C3.3, C4.4 (Mech), and C7.1 (Mech) Engines", to determine if the failure of fuel pump is caused by dirty fuel or customer's maintenance practices, and record facts as specified. Apply this Service Letter program only if the inspection reveals FIP failure that is not attributable to customer's maintenance or use of contaminated / bad fuel.
Remove the existing fuel injection pump, and install a new 463-1678 Fuel Injection Pump Assembly.
Refer to UENR0674, Disassembly and Assembly, C7.1 (Mech) Engines, "Fuel Injection Pump Remove - With Boost Control", and install procedure, in order to complete this Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-5000 hrs,
0-24 mo 100.0% 0.0% 0.0% 100.0% 0.0% 0.0%
This is a 8.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.