101401-7112 ZEXEL 9 400 610 408 BOSCH INJECTION-PUMP ASSEMBLY 9400610408 1014017112

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 408 9400610408

ZEXEL 101401-7112 1014017112

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Service parts 101401-7112 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8510

3. GOVERNOR 105932-1352

4. SUPPLY PUMP 105210-6100

5. AUTOM. ADVANCE MECHANIS 105676-5120

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6051

11. Nozzle and Holder 8-97119-812-0

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

13. NOZZLE-HOLDER 105048-3673

14. NOZZLE

105017-1860

15. NOZZLE SET

Include in #1:

101401-7112 as INJECTION-PUMP ASSEMBLY

106673-3050 as _

106673-3051

Cross reference number

BOSCH 9 400 610 408 9400610408

ZEXEL 101401-7112 1014017112

Zexel num

Bosch num

Firm num

Name

101401-7112
101401-7113

9 400 610 408

INJECTION-PUMP ASSEMBLY
* 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 131424-4920

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 4.1 4.05 4.15

Rack position
Point E R=E

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 11.9

Pump speed r/min 1310 1310 1310

Average injection quantity mm3/st. 64.5 62.9 66.1

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.8+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 15.5 14.2 16.8

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(11.9)

Pump speed r/min 1310 1310 1310

Average injection quantity mm3/st. 64.5 63.5 65.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(11.9)

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 67.5 63.5 71.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 44.7 40.7 48.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point E

Rack position R1-0.05

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 58.5 54.5 62.5

Fixing the lever *

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 5 4.5 5.5

Remarks
Measure the actual speed, stop

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=L31
----------

Speed control lever angle

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

----------
a=41deg+-5deg b=34deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)At pump speed bb and rack position cc, set the stopper bolt. (3)(Actual measurement)
----------
aa=25mm bb=1600r/min cc=5.5-0.5mm
----------
a=15deg+-5deg

0000001501 RACK SENSOR

Rack sensor adjustment 1. Flange type rack sensor (rack sensor adjustment -5*20) (1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures. (2)Mount the rack sensor main body to the pump main body. (3)Fix the pump lever at full. (4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist. (5)Move the pump lever two or three times. (6)Set again to full. (7)Confirm that the amplifier output voltage is Vist. (8)Fix the caution plate to the upper part of the rack sensor. (For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.) (9)Apply red paint to the rack sensor mounting bolts (2 places).
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V1=5+-0.01V N1=960r/min Ra=R1(11.9)-0.05mm Vist=2.61+-0.28V
----------

0000001601 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=440r/min Ra=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Stamping position on the A/T outer rim (4)Pump bracket check hole position. (5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1. (6)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)

Information:

307-OR to S Terminal of Key Switch, 308-YL to R Terminal of Key Switch, 105-BR to B Terminal of Key Switch,7. Connect additional leads to the key switch by loosening the screws and placing 307-OR, 308-YL and 105-BR leads under the screws and tighten. Make sure to match existing wire codes and color.8. Clip EPTC-II data link extension of EUI Retro harness (used for EPTC II) with 3T3048 clip assembly. 9. Remove existing console panel located towards rear of console directly above transmission control box (EPTC).
1053652 Panel Group. 1. 1052038 Plate. 2. 1052484 Film. 3. 6T6066 Switch Assembly. 4. Two 6T6329 Bezel. 5. Four 5P7590 Bolt. 6. 6T3990 Switch Assembly. 7. Four 3E8043 Screw. 8. 8C6354 Cap. 9. Four 5P1075 Washer. 10. 7T0493 Plug. 11. Four 6V8801 Nut. 12. Two 3T0304 Base. 13. Two 7N1996 Lamp. 14. Two 6T7058 Lens. 15. Two 6T2774 Clip. 16. Four 6B4540 Nut. 17. Four 6D3033 Screw. 18. Four 6V9497 Washer. 19. 1049543 Harness Assembly. 20. 1052045 Panel. 1 10. Assemble the 1053652 Panel Group as shown in the illustrations above.
1049543 Harness Assembly11. Connect the harness and individual wires as shown. Clip 1049543 Harness to the panel with 8M2773 Clip.12. Connect the EUI Retro harness to 1049543 Harness Assembly. Clip the connection with a 3T3046 Clip Assembly. Position the panel group back in place on the console with the existing hardware.Cab EUI Retrofit Harness (Front of Cab)
A major portion of the EUI Retro harness will extend through the tunnel to the front of the cab where connections must be made to the:* Overspeed warning light* Throttle pedal* Warning hornOverspeed warning light
Route the front portion of the Retro Harness through the tunnel under the cab. The plate under the cab may be removed for easier access.All trucks after 9ZC133 were equipped with an engine overspeed control module located in the front of the cab. This function is now handled by the EUI-Electronic Control Module. Part of this old system (8W0584 Wiring Group-Cab) must be disconnected and removed.Remove the following items.
8W0584 Wiring Group. 1. 8W7193 Harness Assembly. 2. 7T3821 Control Group. 3. 9D3721 Switch. 4. Two 7N8419 Terminals. 5. Three 4M5282 Bolts. 6. Three 5P4115 Washers.Overspeed Warning Group
All trucks with PINS 9ZC1 thru 9ZC132, a Special Instruction SEHS8863 Installation of Off-Highway Truck Engine Overspeed Warning Indicator Group was available to update these trucks with the stand alone engine overspeed system.This Special Instruction should be used for all trucks within this PIN range.* Trucks that was not retro-fitted with engine overspeed.* Trucks that had been retro-fitted with Special Instruction SEHS8863.Trucks That Was Not Retro-fitted
Install just the items given in the following chart on these trucks. The 12 items in the chart above must be installed to complete the EUI Retro-fit on those trucks that had no overspeed warning installed. The following Steps were taken from Special Instruction SEHS8863. The following Steps are similar to the Steps in SEHS8863. Do only those things that are spelled out in these 12 Steps, which were taken from SEHS8863.1. Disconnect