101401-9260 ZEXEL 9 400 613 802 BOSCH INJECTION-PUMP ASSEMBLY 9400613802 1014019260

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 802 9400613802

ZEXEL 101401-9260 1014019260

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Buy INJECTION-PUMP ASSEMBLY 101401-9260 zexel genuine, new aftermarket engine parts with delivery

Service parts 101401-9260 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8180

3. GOVERNOR 105492-7270

4. SUPPLY PUMP 105210-4870

5. AUTOM. ADVANCE MECHANIS 105622-1880

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5120

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3700

14. NOZZLE

105015-4740

15. NOZZLE SET

Include in #1:

101401-2375 as _

101401-9260 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 802 9400613802

ZEXEL 101401-9260 1014019260

Zexel num

Bosch num

Firm num

Name

101401-9260

9 400 613 802

CHINA

INJECTION-PUMP ASSEMBLY
4102BQ K 14BC INJECTION PUMP ASSY 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 3.6 3.55 3.65

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 10.1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 71 69 73

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8.4 6.9 9.9

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 94 94

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (N = N1) (3)Damper spring setting
----------
SXL=10.6+-0.1mm N1=500r/min
----------

Speed control lever angle

F:Full speed
----------

----------
a=24deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=16deg+-5deg b=26deg+-3deg

Stop lever angle

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

----------
a=35deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(90deg)

Information:

PARTS NEEDED
Qty
Part Number Description
1 7K1181 STRAP-CABLE
1 1325789 CLIP-LADDER
1 4182073 GASKET AS
1 4609257 INJECTOR AS-DEF
1 5407232 SFWR GP-A1000
1 BULK_COOLANT COOLANT See OMM (After Failure Only)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Refer to the attached Rework Procedure.
Reflash the engine controller (ECM) with the software listed in the Parts Needed or latest available on SIS Web.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3001-5000 hrs,
37-60 mo 100.0% 0.0% 0.0% 0.0% 0.0% 100.0%
This is a 2.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
Diesel Exhaust Fluid Pressure Line Rerouting:
1. Unbolt strap (1) from current position.
Loosen clip-loop (2) and reorient the clip on the hose.
Bolt strap to new location (3) and tighten clip-loop to hold the hose in position.
2. Loosen upper clip-loop (4) to allow hose to be pulled through.
3. Add the following parts in the position shown (5);
Clip-ladder, 132-5789
Strap-cable, 7K-1181
4. Tighten upper clip-loop (4) to retain hose in position.
Image1.1.1
DEF Injector Replacement ? Remove and Install:
1. Remove DEF injector and replace. Follow Disassembly and Assembly, UENR6559, for DEF Injector and Mounting - Remove and Install.
Update Engine Software:
Reflash the engine controller (ECM) with the software listed in the Parts Needed or latest available on SIS Web.