101492-9480 ZEXEL 9 400 619 708 BOSCH INJECTION-PUMP ASSEMBLY 9400619708 1014929480 16712na007

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 708 9400619708

ZEXEL 101492-9480 1014929480

NISSAN-DIESEL 16712NA007 16712na007

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Buy INJECTION-PUMP ASSEMBLY 101492-9480 zexel genuine, new aftermarket engine parts with delivery

Service parts 101492-9480 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-4130

3. GOVERNOR 105419-5270

4. SUPPLY PUMP 105220-7020

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-9322

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105119-4170

11. Nozzle and Holder 16600NA002

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3840

14. NOZZLE 105017-9410

15. NOZZLE SET

Include in #1:

101492-9480 as INJECTION-PUMP ASSEMBLY

103860-0122 as _

Cross reference number

BOSCH 9 400 619 708 9400619708

ZEXEL 101492-9480 1014929480

NISSAN-DIESEL 16712NA007 16712na007

Zexel num

Bosch num

Firm num

Name

101492-9480
101492-9481

9 400 619 708

16712NA007 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
BD30T * 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 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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

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 A

Rack position 11

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 72.5 71.5 73.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.3+-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 8 6 10

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point C

Rack position 11.2++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 70 80

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Set at delivery
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)When pump speed set at bb (3)Stopper bolt setting (4)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=(14deg)+-5deg b=(1deg)+-5deg c=(5deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=12deg+-5deg b=53deg+-5deg

Timing setting

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

----------
a=(100deg)

Information:

TECHNICAL INFORMATION BULLETIN March 05, 2003
Articulated Truck
Cold Planer
Landfill Compactor
Excavator
Motor Grader
Off-Highway Truck/Tractor
Quarry Truck
Track-Type Tractor
Underground Articulated Truck
Wheel Loader
Wheel Tractor
Wheel Tractor-Scraper D30C (05A)
PM-565 (3TK)
PM-565B (8GS)
836 (7FR)
5110B (AAA)
24H (7KK)
69D (9SS, 9XS)
73D (1GW)
769D (BBB, 5SS, 5TR)
773D (7ER, 7CS)
771D (BCA, 6JR, 6YS)
775D (6KR, 8AS)
D10R (3KR)
D9R (ABK, ACL, 7TL, 8BL)
AD40 II (1YZ)
AD45 (BKZ)
AE40 II (BLW, 1ZZ)
988F II (2ZR)
990 II (4FR)
834B (7BR)
844 (2KZ)
631E II (1AB1446-Up, 1NB)
631E (1AB1-1445)
631G (AWK)
633E II (2PS)
637E II (1FB532-Up)
637E (1FB1-531)
637G (AXT)
651E (4YR)
657E (5YR, 6PR, 6TR, 7KR)
Component Code: 1901SUBJECT: Flashing New Software When Electronic Control Module (ECM) or Injectors Are Replaced
PROBLEM:
There have been dealer reports of engine ECMs locking up when new software is being installed. Dealer staff may see a message on the service tool such as: "The ECM is not responding to the service tool. Error code 864256". The flashing will typically hang up after 88% complete. When you reconnect, ET will not be able to communicate. Messages you typically get: "The communication adapter was unable to connect to the ATA data link. Error # 441. The requested protocol is not compatible with an existing datalink." You may also see: "The software file and the ECM are not compatible. Process aborted ? Error Code: 147456."
The two new software part numbers are:
222-XXXX (needed when a 172-0802 ECM is replaced by a 156-7156 ECM)
214-YYYY (needed when new-style injectors are installed)
SOLUTION:
If you are considering performing Product Support Program PS50424 on one of the above-listed machines, you may want to delay the program until new software is released. New software will be released in the near future to resolve this issue. Once the flashfiles are in SIS Web, a follow-up TIB will announce the new software?s availability.
On machine engines that have an older ECM that fails (145-7808 or 172-0802), the current 156-7172 production ECM will be needed for parts service. This will require using one of the 222-XXXX flashfiles. To minimize the possibility of locking-up the ECM, the dealer service staff can do one of the following:
Flash the ECM before traveling to the job site. This will require a By-Pass harness.
Flash the ECM on the engine. A By-Pass harness is recommended. If a By-Pass harness is used, disconnect the machine wiring harness before flashing the engine ECM. Dealers report that this method reduces the number of lock-ups.
If the dealer does not have a By-Pass harness, one will have to be purchased or assembled. If a new 129-2018 Wiring Harness Assembly (By-Pass) is purchased, modifications are necessary. Instructions on how to modify a By-Pass harness (Method 1: Modify a By-Pass Harness) and assemble a By-Pass harness (Method 2: Assemble a By-Pass Harness) appear later in this TIB.
Note: When flashing engine ECMs, always download the file from SIS Web to the computer?s hard drive. The service person should then upload (flash) to the ECM from the computer?s hard drive. For a listing of all models affected and the current software, refer to REHS1385-02, "Introduction of New 3408E and 3412E Hydraulic Electronic Unit Injectors".
Method 1: Modify a By-Pass Harness
When flashing an on-engine ECM with the current files, Caterpillar recommends the use