101601-9990 ZEXEL 9 400 614 700 BOSCH INJECTION-PUMP ASSEMBLY 9400614700 1016019990 1670095072

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 700 9400614700

ZEXEL 101601-9990 1016019990

NISSAN-DIESEL 1670095072 1670095072

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Service parts 101601-9990 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3350

3. GOVERNOR 105460-0590

4. SUPPLY PUMP 105220-7050

5. AUTOM. ADVANCE MECHANIS 105614-3360

6. COUPLING PLATE 105661-0601

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5341

11. Nozzle and Holder 16600-95013

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105031-4620

14. NOZZLE

105015-6981

15. NOZZLE SET

Include in #1:

101405-3090 as _

101601-9990 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 614 700 9400614700

ZEXEL 101601-9990 1016019990

NISSAN-DIESEL 1670095072 1670095072

Zexel num

Bosch num

Firm num

Name

101601-9990

9 400 614 700

1670095072 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
NE6 * K 14BE INJECTION PUMP ASSY PE6A 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 132424-0620

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 1-4-2-6- 3-5

Pre-stroke mm 3 2.95 3.05

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 8.8

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 79.4 78.4 80.4

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 68.3 66.3 70.3

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 7.2+-0.5

Pump speed r/min 285 285 285

Average injection quantity mm3/st. 9 7.2 10.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position 13.2+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 115 115

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 800

Advance angle deg. 1.5 1 2

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Damper spring setting: DL
----------
SXL=10+0.2mm DL=6-0.2mm
----------

0000000901

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

----------
a=16.5deg+-5deg b=21deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=20mm
----------
a=40deg+-5deg b=71deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)

Information:

Introduction
Note: Do not perform any procedure in this Special Instruction until the information has been read and understood.Injector Wiring Harness Kit
The new 141-7060 Injector Wiring Harness Kit is available to repair the connectors on the 122-8835 Wiring Harness Assembly or the 133-3745 Wiring Harness Assembly . The connectors on the wiring harness assembly connect to the Hydraulic Electronic Unit Injectors (HEUI) in the above Caterpillar Truck Engines. Each injector wiring harness kit includes:
one connector
two barrel splices
two pieces of heat shrink tubingInstallation Of The 141-7060 Injector Wiring Harness Kit
Carefully remove the valve cover from the engine. Avoid damaging the gasket on the valve cover.
Remove the damaged connector from the HEUI injector solenoid.
Cut the damaged connector from the HEUI injector wiring harness. A length of 31.8 mm (1.25 inch) should remain from the heat shrink tubing on one of the harness wires. A length of 19.1 mm (0.75 inch) should remain from the heat shrink tubing on the other harness wire.Note: DO NOT allow the removed insulation to fall into the cylinder head assembly. DO NOT allow the removed insulation to fall into the open passages of the oil sump.
Remove approximately 8 mm (0.3 inch) of the insulation from the two harness wires.Note: Remove only enough insulation in order to allow the harness wires to seat into the new barrel splice from the injector wiring harness kit.
Remove the two pieces of the heat shrink tubing from the injector wiring harness kit.
Slip the heat shrink tubing from the injector wiring harness kit over the ends of the HEUI injector wiring harness wires.Note: The heat shrink tubing must be pushed far enough onto the harness wires so that the heat shrink tubing will not be cut when crimping the barrel splices. DO NOT crimp through the heat shrink tubing. Crimping through the heat shrink tubing will cause damage.
Remove the replacement connector from the injector wiring harness kit.
Install the replacement connector on the HEUI injector wiring harness wires.
Crimp the two barrel splices to the HEUI injector wiring harness wires.
Move the heat shrink tubing over the exposed barrel splices. Center the barrel splices in the heat shrink tubing.
Use a heat gun to heat the heat shrink tubing. Apply heat until the tubing shrinks evenly around the barrel splices.Note: DO NOT overheat the heat shrink tubing. Damage to the heat shrink tubing may result. The appearance of the heat shrink tubing should be uniform and smooth when properly shrunk.
Connect the repaired HEUI injector wiring harness connector to the HEUI injector solenoid.
Inspect the valve cover gasket for damage. Replace the valve cover gasket if the gasket is damaged.
Install the valve cover gasket. Install the valve cover.
Start the engine. Test the effectiveness of the repair.