Information injection-pump assembly
BOSCH
9 400 616 522
9400616522
ZEXEL
104304-4461
1043044461
ISUZU
8944621771
8944621771
Rating:
Service parts 104304-4461 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
4.
SUPPLY PUMP
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
118.{120}
15.
NOZZLE SET
Include in #1:
104304-4461
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 616 522
9400616522
ZEXEL
104304-4461
1043044461
ISUZU
8944621771
8944621771
Zexel num
Bosch num
Firm num
Name
104304-4461
9 400 616 522
8944621771 ISUZU
INJECTION-PUMP ASSEMBLY
4FC1 * K
4FC1 * 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
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
2.1
2.05
2.15
Rack position
Point B R=B
Point B R=B
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
B
Rack position
8.3
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
35.9
34.9
36.9
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.1+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
8.7
7.7
9.7
Max. variation between cylinders
%
0
-14
14
Fixing the lever
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque control stroke: L1
(2)Set the idle spring.
(3)Main spring setting
(4)Rack difference from N = N1
(5)Rack difference to N = N2
----------
L1=1.1+-0.1mm N1=1300r/min N2=1300r/min
----------
----------
L1=1.1+-0.1mm N1=1300r/min N2=1300r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=7deg+-3deg b=28deg+-6deg
----------
----------
a=7deg+-3deg b=28deg+-6deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=100deg+-5deg b=(38deg)
----------
----------
a=100deg+-5deg b=(38deg)
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=20deg
----------
a=(50deg)
----------
aa=20deg
----------
a=(50deg)
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
30Sep2020
PROBLEM
The existing fuel injectors may start to leak on certain 120K 2 and 140K 2 Motor Graders. This can allow fuel to mix with the engine oil in certain high cycle / heavy engine load applications.
AFFECTED PRODUCT
Model Identification Number
120K 2 SZS00489-01219, 10100-10446, 20100-20452
140K 2 SZW00159-00199, 10100-10113, 20100-20106
PARTS NEEDED
Qty
Part Number Description
6 3879427 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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
If a machine starts to have signs of fuel entering the oil and one fuel injector is found to be leaking. Replace all six fuel injectors using part 387-9427.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-5000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
5001-7500 hrs,
49-84 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 5.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Have questions with 104304-4461?
Group cross 104304-4461 ZEXEL
Isuzu
Isuzu
Isuzu
104304-4461
9 400 616 522
8944621771
INJECTION-PUMP ASSEMBLY
4FC1
4FC1