101401-2420 ZEXEL 9 400 619 484 BOSCH INJECTION-PUMP ASSEMBLY 9400619484 1014012420 220801870a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 484 9400619484

ZEXEL 101401-2420 1014012420

HINO 220801870A 220801870a

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Buy INJECTION-PUMP ASSEMBLY 101401-2420 zexel genuine, new aftermarket engine parts with delivery

Service parts 101401-2420 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9750

3. GOVERNOR 105963-0010

4. SUPPLY PUMP 105220-7590

5. AUTOM. ADVANCE MECHANIS 105676-1340

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8680

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105031-7430

14. NOZZLE

15. NOZZLE SET 105019-2870

Include in #1:

101401-2420 as INJECTION-PUMP ASSEMBLY

108822-3202 as _

108822-3203

Cross reference number

BOSCH 9 400 619 484 9400619484

ZEXEL 101401-2420 1014012420

HINO 220801870A 220801870a

Zexel num

Bosch num

Firm num

Name

101401-2420

9 400 619 484

220801870A HINO

INJECTION-PUMP ASSEMBLY
W04D-TI K 14BL INJECTION PUMP ASSY PE 5MD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8310

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2240

Opening pressure MPa 18

Opening pressure kgf/cm2 184

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-5720

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

RED4 control unit part number 407915-0 590

RED4 rack sensor specifications mm 19

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 3.45 3.42 3.48

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Rack position (11.9)

PWM % 55.3

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 71 70 72

Max. variation between cylinders % 0 -3 3

Basic *

Injection quantity adjustment_02

Rack position (7)

PWM % 27.7+-2. 8

Pump speed r/min 370 370 370

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Governor adjustment

Pump speed r/min 1300--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 1250

Advance angle deg. 0.3

Governor adjustment_03

Pump speed r/min 1400

Advance angle deg. 1.5 1.2 1.8

Governor adjustment_04

Pump speed r/min -

Advance angle deg. 3 3 3

Remarks
Measure the actual speed, stop

Test data Ex:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=20mm bb=1mm
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a=0deg+-5deg b=37deg+-5deg

0000000901

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

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a=(70deg)

Stop lever angle

(PWM) Pulse width modulation (%) (R) Rack position (mm) Rack sensor output characteristics 1. Rack limit adjustment (1)Measure the rack position R2 for PWM a2%. (2)Confirm that it is within the range R2 = 15+-1 mm. (3)Measure the rack position R1 at PWM a %. (4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm. 2. Check the limp home operation. (1)Move the switch box's limp home switch to the limp home side. (2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table. 3. Check the pull down operation. (1)Confirm that the rack position is 19 mm at PWM B%. (2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5 % B=95%
----------

Information:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
Termination Date
March 31, 1997Problem
Improvements have been made to the remanufactured unit injectors that are used in various 3114 and 3116 Engines. All of the former 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors need to be removed from Parts Stock.
Action Required
Remove all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors from Parts Stock.
When ordering parts, refer to the attached chart until the information is available in a permanent publication.
Service Claim Allowances
Submit one claim for all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors removed from Parts Stock.
TEPS Dealers should refer to their warranty bullitin for proper claiming and disposition.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R3002, 0R3003, 0R3190, 0R3389, 0R3580, 0R3742, 0R4368, 0R4369, 0R4370, 0R4374, and 0R4376 Remanufactured Unit Injectors that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn: Bill Harland - Warranty Review
501 Cardinal Drive
Corinth, MS 38834
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on Remanufactured Engines and Components, refer to the topic "Disposition of the Core Under Warranty".
Attach.(1-UNIT INJECTOR CHART)3114 & 3116 Unit Injector Chart