101401-4040 ZEXEL 9 400 613 673 BOSCH INJECTION-PUMP ASSEMBLY 9400613673 1014014040 8970186633

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 673 9400613673

ZEXEL 101401-4040 1014014040

ISUZU 8970186633 8970186633

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Buy INJECTION-PUMP ASSEMBLY 101401-4040 zexel genuine, new aftermarket engine parts with delivery

Service parts 101401-4040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-8840

3. GOVERNOR 105931-7251

4. SUPPLY PUMP 105210-6480

5. AUTOM. ADVANCE MECHANIS 105676-5001

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5110

11. Nozzle and Holder 8-94388-787-0

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

13. NOZZLE-HOLDER 105048-3550

14. NOZZLE 105017-1130

15. NOZZLE SET

Include in #1:

101401-4040 as INJECTION-PUMP ASSEMBLY

106873-3630 as _

Cross reference number

BOSCH 9 400 613 673 9400613673

ZEXEL 101401-4040 1014014040

ISUZU 8970186633 8970186633

Zexel num

Bosch num

Firm num

Name

101401-4040
101401-4090

9 400 613 673

8970186633 ISUZU

INJECTION-PUMP ASSEMBLY
4HF1 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8210

Nozzle 105780-0070

Bosch type code DN12SD12T-1

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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 3.9 3.85 3.95

Rack position
Point A R=A

Beginning of injection position
Governor 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 12.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 72.8 71.2 74.4

Max. variation between cylinders % 0 -2.5 2.5

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 350 350 350

Average injection quantity mm3/st. 8.4 7.1 9.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.8)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 72.8 71.8 73.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 88.5 84.5 92.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 80 80 112

Fixing the lever *

Timer adjustment

Pump speed r/min 1375--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1325

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1575

Advance angle deg. 5 4.5 5.5

Remarks
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.
----------
T1=E87
----------

Speed control lever angle

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

----------
a=40deg+-5deg b=(34deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg

0000001501 FICD

(A) applied negative pressure (B) Screw (c) Nut 1. Set the actuator as described below. (1)Confirm that there is clearance between the actuator lever and the speed lever. (2)Loosen the nut (C). (3)Push in the screw (B). (4)Apply P1 from the actuator (A) part. (5)Pull out the screw (B) slowly. (6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra. (7)Torque the nut (C) to T1. (8)Apply P2 several times. (9)Confirm that the actuator functions normally. (10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=500r/min Ra=9.55+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(2)mm

0000001601 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=1100r/min Ra=9+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(60deg)

Information:

This Program can only be administeredafter a failure occurs. The decision whether to apply the Program is madeby the dealer. When reporting the repair, use "PS50780" as the Part numberand "7755" as the Group Number. Use "96" as the Warranty Claim DescriptionCode and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe April 2, 2004 (Revised April 2004) Service Letter. Changes have beenmade to the Affected Product.TERMINATION DATE
April 30, 2006PROBLEM
Failed injector and wiring harness need to bereplaced on certain C-9 Industrial Engines. The C-9 engine can developan injector misfire due to an open connection at the injector to harnessconnector. This misfire can be diagnosed with standard troubleshootingguide procedures.AFFECTED PRODUCT
Model Identification Number
C9 CLJ1-4259
12H 12500001-40AMZ1-496CBK1-353
330C B1K1-178B2L1-203B4N1-187BTM1-189CGZ1-511CYA1-287D3C1-231JAB1-626JCD1-292JNK1-245KDD1-580MCA1-427MKM1-308GAG1-329RBH1-233
330C L CAP1-1257DKY1-2011HAA1-393
D6R II AEM1-100AFM1-115BLE1-199BLT1-186BMK1-121BNL1-99BPM1-101BPP1-97BPS1-102BRJ1-116
D6R II LGP ACJ1-101ADE1-311BNC1-265BPZ1-142
D6R II XL AAX1-465BMJ1-130BMY1-297BRZ1-115CAD1-143FDT1-141
D6R II XW AEP1-223DAE1-129
470 7651-811
475 7671-824
MT765 AMS1-266
TK711 10100001-00191
TK721 10200001-00191
TK722 10300001-00193
TK732 10400185-00190
627G CEX187-296
637G CEH222-255PARTS NEEDED
Qty
Part Number
Description
1 1567106 Wiring Kit
1 1889865 Harness Assembly
1 2359651 Bolt - Socket
1 2360962 Injector GroupACTION REQUIRED
Replace the single failed injector with the new 2360962 Injector and the1889865 Wiring Harness Assembly. Refer to REHS1809 Special Instructionfor use of the 1567106 Wiring Kit.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
0-35 months 100% 2.0 0 0 0 0
This is a 2?hour job.PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warrantyparts handling.