101491-9183 ZEXEL F 019 Z20 451 BOSCH INJECTION-PUMP ASSEMBLY f019z20451 1014919183 16700t9307

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 451 f019z20451

ZEXEL 101491-9183 1014919183

NISSAN-DIESEL 16700T9307 16700t9307

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Service parts 101491-9183 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9142

3. GOVERNOR 105921-0940

4. SUPPLY PUMP 105220-4840

5. AUTOM. ADVANCE MECHANIS 105670-0100

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6830

11. Nozzle and Holder 16600-T9303

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

13. NOZZLE-HOLDER 105031-4600

14. NOZZLE

105015-6490

15. NOZZLE SET

Include in #1:

101491-9183 as INJECTION-PUMP ASSEMBLY

101605-3401 as _

Cross reference number

BOSCH F 019 Z20 451 f019z20451

ZEXEL 101491-9183 1014919183

NISSAN-DIESEL 16700T9307 16700t9307

Zexel num

Bosch num

Firm num

Name

101491-9183

F 019 Z20 451

16700T9307 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD33 * K 14BC PE4A,5A, 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 131424-6120

Overflow valve opening pressure kPa 191 157 225

Overflow valve opening pressure kgf/cm2 1.95 1.6 2.3

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 1-3-4-2

Pre-stroke mm 3.4 3.35 3.45

Rack position
Point A R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 9.5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 41.5 39.5 43.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.1+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 10 8 12

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 41.5 40.5 42.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.4

Pump speed r/min 1800 1800 1800

Average injection quantity mm3/st. 52.2 48.2 56.2

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.1

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 38 34 42

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.85

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 33.7 33.7

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 66 66 86

Fixing the lever *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 1.75 1.25 2.25

Timer adjustment_04

Pump speed r/min 1800

Advance angle deg. 3.5 3 4

Timer adjustment_05

Pump speed r/min 1850

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Torque cam set point
----------
T1=A89
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=25deg+-5deg b=39deg+-3deg

Stop lever angle

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

----------
a=7deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear mark 'N') at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(60deg)

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.