Information injection-pump assembly
BOSCH
F 019 Z20 472
f019z20472
ZEXEL
101603-9572
1016039572
NISSAN-DIESEL
16713Z5862
16713z5862
Rating:
Service parts 101603-9572 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-Z5600
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101603-9572
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-5760
as _
Cross reference number
BOSCH
F 019 Z20 472
f019z20472
ZEXEL
101603-9572
1016039572
NISSAN-DIESEL
16713Z5862
16713z5862
Zexel num
Bosch num
Firm num
Name
F 019 Z20 472
16713Z5862 NISSAN-DIESEL
INJECTION-PUMP ASSEMBLY
FE6A * K 14BE PE6A PE
FE6A * K 14BE PE6A PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3
2.95
3.05
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.2
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
61.6
60
63.2
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
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
8.7
6.9
10.5
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.2)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
61.6
60.6
62.6
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.05
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
72.7
68.7
76.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
81
81
91
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
(1140)
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1500
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
----------
T1=G12
----------
----------
T1=G12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=27.5deg+-5deg b=(41deg)+-3deg
----------
----------
a=27.5deg+-5deg b=(41deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=20deg+-5deg b=40deg+-5deg
----------
----------
a=20deg+-5deg b=40deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Engine Runs Smoothly
Possible Causes/CorrectionsDirty Air Cleaner
If the air cleaner has a restriction indicator, see if the red piston is in view. If there is no restriction indicator, restriction can be checked with a water manometer or a vacuum gauge (which measures in inches of water). Make a connection to the piping between the air cleaner and the inlet of the turbocharger. Check with the engine running at full load rpm. Maximum restriction is 635 mm (25 in) of water. If a gauge is not available, visually check the air cleaner element for dirt. If the element is dirty, clean the element or install a new element.Air Inlet Piping Damage or Restriction
Make a visual inspection of the air inlet system and check for damage to piping, rags in the inlet piping, or damage to the rain cap or the cap pushed too far on the inlet pipe. If no damage is seen, check inlet restriction with a clean air cleaner element.Exhaust System Restriction
Make a visual inspection of the exhaust system. Check for damage to piping or for a bad muffler. If no damage is found, you can check the system by checking the back pressure from the exhaust (pressure difference measurement between exhaust outlet and atmosphere). The back pressure must not be more than 1016 mm (40 in) of water. You can also check by removing the exhaust pipes from the exhaust manifolds. With the exhaust pipes removed, start and load the engine on a chassis dynamometer to see if the problem is corrected.Fuel Injection Timing Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual.Fuel Setting Is Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. See the Fuel Setting And Related Information Fiche for the correct fuel setting.Low Quality Fuel
Test the engine with fuel according to recommendations by Caterpillar Inc. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines. Also, Special Instruction, Form No. SEHS6947 has fuel correction factors and tables.Bad Fuel Nozzle(s)
Bad fuel nozzles will normally cause the engine to misfire and run rough, but can cause too much smoke with engine still running smooth. Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual.Wrong Seal Washer Installed Under Nozzle(s)
The use of incorrect washers change the location of the fuel injection nozzles in the combustion chamber. This effects smoke. Check the Engine Arrangement for the correct part number to use.Valve Adjustment Not Correct or Valve Leakage
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in) and exhaust valve clearance is 0.76 mm (.030 in). Valve leakage normally causes the engine to misfire and run rough.Bad Fuel Injection Pump
An injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the
Possible Causes/CorrectionsDirty Air Cleaner
If the air cleaner has a restriction indicator, see if the red piston is in view. If there is no restriction indicator, restriction can be checked with a water manometer or a vacuum gauge (which measures in inches of water). Make a connection to the piping between the air cleaner and the inlet of the turbocharger. Check with the engine running at full load rpm. Maximum restriction is 635 mm (25 in) of water. If a gauge is not available, visually check the air cleaner element for dirt. If the element is dirty, clean the element or install a new element.Air Inlet Piping Damage or Restriction
Make a visual inspection of the air inlet system and check for damage to piping, rags in the inlet piping, or damage to the rain cap or the cap pushed too far on the inlet pipe. If no damage is seen, check inlet restriction with a clean air cleaner element.Exhaust System Restriction
Make a visual inspection of the exhaust system. Check for damage to piping or for a bad muffler. If no damage is found, you can check the system by checking the back pressure from the exhaust (pressure difference measurement between exhaust outlet and atmosphere). The back pressure must not be more than 1016 mm (40 in) of water. You can also check by removing the exhaust pipes from the exhaust manifolds. With the exhaust pipes removed, start and load the engine on a chassis dynamometer to see if the problem is corrected.Fuel Injection Timing Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual.Fuel Setting Is Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. See the Fuel Setting And Related Information Fiche for the correct fuel setting.Low Quality Fuel
Test the engine with fuel according to recommendations by Caterpillar Inc. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines. Also, Special Instruction, Form No. SEHS6947 has fuel correction factors and tables.Bad Fuel Nozzle(s)
Bad fuel nozzles will normally cause the engine to misfire and run rough, but can cause too much smoke with engine still running smooth. Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual.Wrong Seal Washer Installed Under Nozzle(s)
The use of incorrect washers change the location of the fuel injection nozzles in the combustion chamber. This effects smoke. Check the Engine Arrangement for the correct part number to use.Valve Adjustment Not Correct or Valve Leakage
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in) and exhaust valve clearance is 0.76 mm (.030 in). Valve leakage normally causes the engine to misfire and run rough.Bad Fuel Injection Pump
An injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the