101491-1240 ZEXEL 9 400 614 313 BOSCH INJECTION-PUMP ASSEMBLY 9400614313 1014911240 me080221

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 313 9400614313

ZEXEL 101491-1240 1014911240

MITSUBISHI ME080221 me080221

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Service parts 101491-1240 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9020

3. GOVERNOR 105921-2230

4. SUPPLY PUMP 105220-5150

5. AUTOM. ADVANCE MECHANIS 105676-0050

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4040

11. Nozzle and Holder ME790067

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

13. NOZZLE-HOLDER 105048-3000

14. NOZZLE

105017-0040

15. NOZZLE SET

Include in #1:

101491-1240 as INJECTION-PUMP ASSEMBLY

101602-3982 as _

Cross reference number

BOSCH 9 400 614 313 9400614313

ZEXEL 101491-1240 1014911240

MITSUBISHI ME080221 me080221

Zexel num

Bosch num

Firm num

Name

101491-1240

9 400 614 313

ME080221 MITSUBISHI

INJECTION-PUMP ASSEMBLY
4D31T K

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 131424-5620

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 3.5 3.45 3.55

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 -

Rack position 11.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 59.5 58.5 60.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10 8.7 11.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.2)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 59.5 58.5 60.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 66 66 71

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1400

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1650

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=A24
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=26deg+-5deg b=(41deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=33deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(130deg)

Information:

November 10, 2003
U-307
A-211
D-227
O-256
TT-24
TM-7
Partsstock action only PRODUCT IMPROVEMENT PROGRAM FOR REMOVINGCERTAIN REMAN FUEL INJECTORS FROM DEALER PART STOCK
7750 PI70071
The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst.TERMINATION DATE
February 29, 2004PROBLEM
Certain fuel injectors need to be removed fromdealer part stock. A number of fuel injectors were built with a Valve OpeningPressure (VOP) spacer that missed a hardening operation. This non-hardenedspacer allows premature wear, causing several operational problems whichmay include: engine misfire, low power, white smoke, and engine would notstart.ACTION REQUIRED
Only remove engine injectors within the suspectdate code range from your parts supply.
In order to perform this inspection, injectorsmust be removed from the packaging.
Repackage all injectors.
Illustration 1 (3406E, C15) Illustration 2 (C10, C12)SERVICE CLAIM ALLOWANCES
Submit one claim for all 0R4667, 0R4893, 0R4894,0R4895, 0R9256, 0R9257, 0R9258, 0R9259, 0R9803, 0R4986, 0R4987, 0R4988,0R7549, 0R8773, 0R8780, and 0R9530 removed from parts stock. Remove onlythose injectors from the suspect serial number range listed below. 0R4667, 0R4893, 0R4894, 0R4895, 0R9256,0R9257, 0R9258, 0R9259, and 0R9803 3406E and C15 injectors should be removedif the serial number is between 318224-371662. 0R4986, 0R4987, 0R4988, 0R7549, 0R8773,0R8780, and 0R9530 C10 and C12 injectors should be removed if the serialnumber is between 34768-47935.PARTS DISPOSITION
These remanufactured parts need to be returnedwith dealer normal core returns in order to allow for core deposit refund.