Information injection-pump assembly
BOSCH
9 400 613 863
9400613863
ZEXEL
101402-2230
1014022230
HINO
220203980A
220203980a

Rating:
Service parts 101402-2230 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1700
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 863
9400613863
ZEXEL
101402-2230
1014022230
HINO
220203980A
220203980a
Zexel num
Bosch num
Firm num
Name
101402-2230
9 400 613 863
220203980A HINO
INJECTION-PUMP ASSEMBLY
W04C-T K
W04C-T K
101402-2230
9 400 613 863
S220203980A HINO
INJECTION-PUMP ASSEMBLY
W04C-T A K
W04C-T A K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.1
3.05
3.15
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
7.4
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
68.6
66.6
70.6
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6+-0.5
Pump speed
r/min
360
360
360
Average injection quantity
mm3/st.
10.1
8.6
11.6
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
97
97
107
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment

N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Rack difference between N = N1 and N = N2
(4)Idle sub spring setting: L1.
----------
K=11 N1=750r/min N2=350r/min L1=5.3-0.5mm
----------
----------
K=11 N1=750r/min N2=350r/min L1=5.3-0.5mm
----------
Speed control lever angle

F:Full speed
I:Idle
S:Stop
(1)Set the pump speed at aa
(2)Set the pump speed at bb.
(3)Stopper bolt setting
(4)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=(5eg)+-5deg b=(4deg)+-5deg c=32deg+-3deg d=(18deg)+-5deg
----------
aa=750r/min bb=900r/min
----------
a=(5eg)+-5deg b=(4deg)+-5deg c=32deg+-3deg d=(18deg)+-5deg
Stop lever angle

N:Pump normal
S:Stop the pump.
(1)Rack position aa or less, pump speed bb
----------
aa=5.5mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg
----------
aa=5.5mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg
Timing setting

(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
Information:
This is a 4.7-hour job for Group 1
Dealer to perform most economical repair.
Description______________SMCS CODE________Hours
Pump Replacement
Engine Wash______________1251-074_________0.3
R&I Pump ________________1251-010_________4.1
Minor Road Test__________1000-530_________0.3
Exception maybe considered and claimed depending on chassis type.
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 0.6-hour job for Group 2
Dealer to perform most economical repair.
Option 1:
0.6 hours will be allowed to inspect the pump when the inspection determines pump serial number is not listed and pump replacement is not necessary.
Description______________SMCS CODE________Hours
Inspect Serial Number____1251-035_________0.6
Option 2 Pump Replacement:
4.7 Hours will be allowed to inspect and replace the pump when the inspection determines the pump serial number is listed and pump replacement is performed.
Description______________SMCS CODE________Hours
Engine Wash______________1251-074_________0.3
R&I Pump ________________1251-010_________4.1
Minor Road Test__________1000-530_________0.3
Exception maybe considered and claimed depending on chassis type.
PARTS DISPOSITION
***** U.S. and Canadian Dealers *****
Make sure the outside of the shipping
container is marked PIXXXX.
Return all Fuel Injection Pumps that are replaced and a copy of the
claim to:
Caterpillar Inc.
Attn: PIXXXXX
BUILDING DD DOCK 8
ROUTE 29 OLD GALENA ROAD
MOSSIVILLE, IL 61552
***** All Other Dealers *****
Handle the parts in accordance with your Warranty Bulletin on
warranty parts handling.
Attach. (1-Owner Notification)
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
IMPORTANT: SAFETY
SAFETY ? RECALL FOR REPLACING THE FUEL PUMP
MODELS INVOLVED - C7 and C9 Truck Engines
Dear Caterpillar Product Owner:
This notice is sent to you in accordance with the requirements of the National Traffic and Motor Vehicle Safety Act. This notice is also in accordance with the requirements of the Canadian Motor Vehicle Safety Act. Caterpillar has decided that a defect which relates to motor vehicle safety exists in trucks equipped with certain Caterpillar C7 & C9 engines.
A fuel pump failure will dilute the engine oil with fuel and may cause the turbocharger to fail and cause loss of throttle control and excessive smoke, both of which may result in a situation where a vehicle crash could occur. A new fuel pump will be installed on the engine. You will not be charged for the service performed.
If you are a lessor of these vehicles, you must forward this letter to your lessee within ten days.
If you have had your vehicle repaired prior to receipt of this notice and incurred any costs, you may be eligible for reimbursement. Please contact Caterpillar at this toll free number (800) 447-4986.
If you no longer own vehicle with this engine, please contact Caterpillar at this toll free number (800) 447-4986.
If the dealer is unable to have the repair made, please contact:
Caterpillar Inc.
PO Box 610
Mossville, IL 61552-610
Attn: Engine Products Division
Truck Engine Call Center
Telephone: (800) 447-4986
If you are unable to have the repair made within 60 days or without charge, you may submit a complaint to:
In the U.S.
Administrator
National Highway Traffic Safety Administration
1200 New Jersey Avenue, S.E.
Washington, D.C. 20590
Telephone: 1-888-327-4236 (TTY:1-800-424-9153)or go to http://www.safercar.gov
In Canada
Transport Canada
Road Safety and Motor Vehicle Regulation
Ottawa, Ontario KIA 0N5
Telephone: (613) 993-9851
Caterpillar Inc.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service. Please refer the dealer to their Service Letter dated -, 2007 when scheduling this service.
We
Have questions with 101402-2230?
Group cross 101402-2230 ZEXEL
Hino
101402-2230
9 400 613 863
220203980A
INJECTION-PUMP ASSEMBLY
W04C-T
W04C-T
101402-2230
9 400 613 863
S220203980A
INJECTION-PUMP ASSEMBLY
W04C-T
W04C-T