104760-4460 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047604460 1670051n04

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 104760-4460 1047604460

NISSAN-DIESEL 1670051N04 1670051n04

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Cross reference number

ZEXEL 104760-4460 1047604460

NISSAN-DIESEL 1670051N04 1670051n04

Zexel num

Bosch num

Firm num

Name

104760-4460
104760-4461

1670051N04 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
TD42 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

Transfer pump pressure kPa 20 20 20

Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side)
Right R

(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF. OFF

Injection timing adjustment

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 46.3 45.8 46.8

Basic *

Oil temperature degC 48 46 50

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 700 700 700

Boost pressure kPa 16 14.7 17.3

Boost pressure mmHg 120 110 130

Average injection quantity mm3/st. 53.7 53.2 54.2

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 58.3 57.8 58.8

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 46.3 45.3 47.3

Basic *

Oil temperature degC 48 46 50

Injection timing adjustment_05

Pump speed r/min 700 700 700

Boost pressure kPa 16 14.7 17.3

Boost pressure mmHg 120 110 130

Average injection quantity mm3/st. 53.7 52.7 54.7

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 51.1 48.6 53.6

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 58.3 57.3 59.3

Difference in delivery mm3/st. 4.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_08

Pump speed r/min 2000 2000 2000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 61.1 58.6 63.6

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 18.3 16.3 20.3

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2500 2500 2500

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 5

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2100 2100 2100

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 55.2 50.7 59.7

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 18.3 15.8 20.8

Basic *

Oil temperature degC 52 50 54

Governor adjustment

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12.5 10.5 14.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12.5 10 15

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 58 48 78

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 58 48 78

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Overflow quantity with S/T ON cm3/min 420 290 550

Oil temperature degC 50 48 52

Remarks
With an O-ring

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Overflow quantity with S/T ON cm3/min 470 340 600

Oil temperature degC 50 48 52

Remarks
Without an O-ring

Stop lever angle

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T ON kPa 431 392 470

Pressure with S/T ON kgf/cm2 4.4 4 4.8

Pressure with S/T OFF kPa 333 304 362

Pressure with S/T OFF kgf/cm2 3.4 3.1 3.7

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T OFF kPa 333 294 372

Pressure with S/T OFF kgf/cm2 3.4 3 3.8

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1700 1700 1700

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Pressure with S/T OFF kPa 549 510 588

Pressure with S/T OFF kgf/cm2 5.6 5.2 6

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T ON mm 4.8 4.4 5.2

Timer stroke with S/T OFF mm 2.6 2.4 2.8

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 800 800 800

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T OFF mm 1.1 0.6 1.6

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T ON mm 4.8 4.3 5.3

Timer stroke with S/T OFF mm 2.6 2.3 2.9

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1700 1700 1700

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T OFF mm 7 6.5 7.4

Oil temperature degC 50 48 52

_05

Pump speed r/min 2000 2000 2000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Timer stroke with S/T OFF mm 7 6.5 7.4

Oil temperature degC 50 48 52

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 38 37.5 38.5

Timer stroke TA mm 2.3 2.3 2.3

Timer stroke variation dT mm 0.3 0.1 0.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 38 37 39

Timer stroke variation dT mm 0.3 0 0.6

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 53.3 52 54.6

Boost pressure mmHg 400 390 410

Average injection quantity mm3/st. 26 23.5 28.5

Timer stroke variation dT mm 0.8 0.4 1.2

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.64 6.54 6.74

MS dimension mm 1 0.9 1.1

BCS stroke mm 1.8 1.6 2

Control lever angle alpha deg. 10 6 14

Control lever angle beta deg. 40 35 45

Test data Ex:

0000001601 BOOST COMPENSATOR ADJUSTMENT

BCS adjustment procedure 1. At full boost pressure, set so that the full injection quantity is within the specifications (adjusting point). 2. Perform boost compensator intermediate operation point adjustment (pump speed N1, boost pressure P1). 3. When injection quantity at boost pressure P2 and pump speed N2 is not as specified, loosen nut (A) and adjust position of screw (B) so that injection quantity is as specified. The screw position should be within +-1 turn of initial position. 4. The nut tightening torque is T.
----------
N1=700r/min N2=500r/min P1=16.0kPa(120mmHg) P2=0kPa(0mmHg) T=6~9N-m(0.6~0.9kgf-m)
----------
SW=10mm T=6~9N-m(0.6~0.9kgf-m)

0000001801 POTENTIOMETER ADJUSTMENT

Potentiometer adjustment 1. Applied voltage: Vi 2. Boost pressure = P1 3. Set the control lever at the adjusting point. Position the dummy bolt against the lever and fix. 4. Assemble the potentiometer to obtain output voltage V1 at the fixed position. 5. After mounting the potentiometer, remove the dummy bolt. N:Pump speed Q:Injection quantity V:Output voltage C:Position of the control lever A:Adjusting point C1:Idle C2:Full-speed
----------
V1=5.52+-0.03V P1=0kPa(0mmHg) Vi=10V
----------
N1=850r/min Q1=13.8+-1.0mm3/st V1=5.52+-0.03V V2=2.42+-0.78V V3=(10V) a=-

Information:

04Feb2016
U-58
A-46
D-55
O-52
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 398-1498 AND 463-1678 FUEL INJECTION PUMPS FROM DEALER PARTS STOCK
7750 PI70604
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
31May2016
PROBLEM
The existing 398-1498 and 463-1678 Fuel Injection Pumps can fail. Fuel Injection Pumps up to and inclusive of component serial number 06369GJG, are suspect.
ACTION REQUIRED
Inspect all 398-1498 and 463-1678 Fuel Injection Pumps in dealer parts stock. Review the component serial number on each 398-1498 and 463-1678 Fuel Injection Pump. The Fuel Injection Pump component serial number can be located on the Fuel Injection Pump data plate, affixed to the side of the Fuel Injection Pump body.
The Fuel Injection Pump component serial number is alphanumeric, Refer to Image 1 for explanation on component serial number translation. In the given example the date code would translate to the following - 6369th pump built in July 2015.
NOTE - The build facility is not applicable in determining if the Fuel Injection Pump is suspect or not.
Refer to Image 2 for the build month and build year translation table.
Please action according to the following build month and build year color code -
Red = Remove from dealer part stock
Orange = Check Fuel Injection Pump Serial Number (06369 and below = Remove from dealer part stock / 06370 and Up = Return to dealer part stock).
Green = OK, Return to dealer part stock.
- If the Fuel Injection Pump is removed from dealer parts stock. Refer to the Service Claim Allowances and Parts Disposition.
- If the Fuel Injection Pump is returned to dealer parts stock, mark the box as inspected.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all Fuel Injection Pumps removed from dealer parts stock. Include the date code (e.g. 06369GJG) in the claim story for each Fuel Injection Pump removed from dealer parts stock.
PARTS DISPOSITION
NACD:
Hold all 398-1498 and 463-1678 Fuel Injection Pumps removed from dealer parts stock for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing