101402-2301 ZEXEL 9 400 610 438 BOSCH INJECTION-PUMP ASSEMBLY 9400610438 1014022301 220204961a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 438 9400610438

ZEXEL 101402-2301 1014022301

HINO 220204961A 220204961a

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Buy INJECTION-PUMP ASSEMBLY 101402-2301 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-2301 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9300

3. GOVERNOR 105400-7350

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-8820

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4320

11. Nozzle and Holder 23600-1710A

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-6240

15. NOZZLE SET

Include in #1:

101402-2301 as INJECTION-PUMP ASSEMBLY

107691-3244 as _

Cross reference number

BOSCH 9 400 610 438 9400610438

ZEXEL 101402-2301 1014022301

HINO 220204961A 220204961a

Zexel num

Bosch num

Firm num

Name

101402-2301

9 400 610 438

220204961A HINO

INJECTION-PUMP ASSEMBLY
W04C-T 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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 3.2 3.17 3.23

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

Adjusting point A

Rack position 9.9

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 90 88 92

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.3+-0.5

Pump speed r/min 280 280 280

Average injection quantity mm3/st. 11.5 10 13

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm.
----------
K=10
----------

Speed control lever angle

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

----------
a=17deg+-5deg b=30deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position aa or less, pump speed bb
----------
aa=6.8mm 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)

Information:

This Program can only be administered after a failure occurs.The decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS51584" as the Part Numberand "7755" as the Group Number. Use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
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
30Nov2010
PROBLEM
The existing fuel injector can fail on certain C32 Marine Engines. If the existing fuel injector fails it will cause a dead injector resulting in no fuel being delivered to cylinder.
AFFECTED PRODUCT
Model Identification Number
C32 RNC02662, 2722, 2726, 2731-2735, 2737-2747, 2749-2759, 2762-2766, 2768-2770, 2772, 2778, 2782, 2787-2788, 2791-2796, 2798, 2800-2818, 2820-2824, 2826-2834, 2836, 2839-2854, 2856-2866, 2868-2878, 2880-2883, 2885-2888, 2892-2895, 2897-2903, 2905-2906, 2908-2910, 2912-2918, 2920-2933, 2935-2936, 2938-2939, 2941, 2944-2947, 2949-2952, 2954-2963, 2965, 2969-2971, 2973-2986, 2988, 2990-3009, 3014-3035, 3037-3039, 3041-3127, 3129-3134, 3136, 3139, 3142-3172, 3174, 3177-3197
RND00101-00103, 114, 123-124, 132-133, 136-146, 151, 159-160, 192-194, 202, 204, 207, 210, 221, 228-249, 251, 253-254, 256-257, 263, 266-267, 270-271, 274-275, 277
RNE00102-00103, 106-111, 114-116, 118-119, 121, 124
RNR00100-00101, 103, 105-107, 109-110, 112-113, 115
T3T00101-00104, 106-110, 112-123, 128, 137-144, 147-148, 190
PARTS NEEDED
Qty
Part Number Description
12 2768307 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 3% 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
After failures of a single injector, replace all 12. See RENR8628 for Disassembly and Assembly instructions.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-100 hrs 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 11.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.