09200-04581 PUMP ASSY, INJECTI Calibration Data


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Information pump assy, injecti Denso

Components :

00.001
PUMP ASSY, INJECTI
NB6,R901
01.002
GOVERNOR ASSY, MEC
R901
02.003
LEVER SET
ADJUST L
02.004
COMPENSATOR SUB-AS
01.005
TIMER ASSY, AUTOMA
SB1
01.006
PUMP ASSY, FUEL FE
KD
01.007
COUPLING ASSY
SD
01.008
BODY ASSY, INJECTI
NB6
02.009
COVER, BEARING
DUMMY

Scheme #.#:

Qty
Part num
Name
Remarks
Manufacture num
000
[01]
09200-04581
PUMP ASSY, INJECTI
NB6,R901
22010-8801 HINO
003
[01]
BODY ASSY, INJECTI
NB6
22110-3660A HINO
004
[01]
GOVERNOR ASSY, MEC
R901
S2231-06820-A HINO
005
[01]
TIMER ASSY, AUTOMA
SB1
S2251-02830-A HINO
006
[01]
NUT, TIMER ROUND
M18X1.5
S2282-52240-A HINO
007
[01]
COUPLING ASSY
SD
S2261-01860-A HINO
008
[01]
KEY, WOODRUFF
W5,H7.5
S2289-11070-A HINO
009
[01]
PUMP ASSY, FUEL FE
KD
S2257-01750-A HINO
010
[01]
COVER, CONTROL RAC
S2211-41200-A HINO
011
[01]
WASHER, COPPER PLA
T1.5
SL722-02215 HINO
012
[01]
BOLT, W/WASHER
M8,L20
S2281-53230-A HINO
013
[04]
BOLT, W/WASHER
M8,L16
S2281-53210-A HINO
014
[01]
BOLT, W/WASHER
M8,L22
S2281-53240-A HINO
015
[02]
BOLT, W/WASHER
M8,L14
S2281-53320-A HINO
018
[01]
CAP
FOR MAX.SPEED
S2232-31210-A HINO
019
[01]
CAP
FOR FULL-LOAD
S2232-31430-A HINO
021
[02]
WASHER
T1,D15.9
S2284-71940-A HINO
022
[01]
VALVE ASSY, OVERFL
MARK 45
S2210-71570-A HINO
025
[02]
BOLT, FLANGE
M8,L20
S2281-53390-A HINO
026
[01]
STAY, INJECTION PU
S1140-91270-C HINO
027
[01]
CAP
FOR MAX.SPEED
S2232-31210-A HINO

Include in ##:

09200-04581 as PUMP ASSY, INJECTI

Cross reference number



Part num
Firm num
Firm
Name
09200-04581 
22010-8801 
PUMP ASSY, INJECTI

Test Calibration Data:

0920004581 22010-8801A1




Information:

Problem
Some fuel injectors may fail on certain Challenger 75 Tractors and 3176 Truck Engines.
Affected Product
Model & Identification Number
Challenger 75 (4CJ1-406)
3176 (2YG1-Up; 7LG1-4822)
Parts Needed
Use the following parts in quantities needed to perform repairs. The application of each injector listed is noted. Use remanufactured injectors, unless unavailable.
0R3397 Injector Grp. (4P9510 if reman unavailable for 7LG 250-300 HP)0R3398 Injector Grp. (4P9520 if reman unavailable for 7LG 325 HP and 4CJ)0R3399 Injector Grp. (4P9610 if reman unavailable for 2YG 250-275 HP)0R3400 Injector Grp. (4P9620 if reman unavailable for 2YG 300-325 HP)9X7557 Seal (injector upper O-ring)9X7722 Seal (injector lower O-ring)336044 Seal (injector thrust-pad-retaining O-ring)Action Required
1. Isolate the injector which is causing the problem. Some failure modes require duplication of the conditions where the customer say the problem occurs (i.e. at full load, idle, high speed, low speed, etc.)2. Replace injectors only after verifying a problem using the 1U6661 Unit Injector Tester, cutting out cylinders, etc. Replace any failed injectors according to the rework procedures attached.Service Claim Allowances
This is a 2.5-hour job. Add 0.2 hours for 1st injector diagnostic test and 0.1 hours for each additional injector test. Add 1.2 hours for first injector sleeve replaced and 0.7 hours for each additional sleeve replaced.
3176 Truck Engines
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
1. Drain fuel from the cylinder head and fuel manifold. Remove air inlet piping, valve covers and Jake Brake (if equipped) , rocker arm assemblies, and injector hold down bolts. Remove the suspect injector(s) for inspection and test. Mark each injector to denote the cylinder from which it was removed. It is important to install the injector(s) into the same cylinder to prevent combustion gas leaks.2. Test the injector(s) using the 1U6661 Unit Injector Tester. Check for leaks, VOP, and spray pattern. Replace all injectors which do not pass these test.Procedure For Installing The Following Injector Part Numbers:
4P1410, 4P1420, 4P2810, 4P2820, 0R3177, AND 0R3178
1. Inspect the raised edge on the injector cone for signs of damage. If any nicks or dings are present, do not reuse the injector.2. Ream the sleeves before installing the injectors. Ream only until the sleeve has been cut to provide a full length concentric taper past the injector/sleeve sealing interface. Full removal of the indentation created by the cone step edge is not necessary.3. Install new O-rings on the injector and apply STP ® to prevent cutting during installation.4. Install the injectors, apply 6V4876 Molykote to the hold-down bolt threads and tighten the bolts to 33 NM (24 ft. lb.). Make sure the longer 5P8347 Bolts and 4P8525 Spacers (or 8T0100 Bolts and 4P1711 Spacers) are used.5. Inspect bridge assemblies for wear.Procedures For Installing All Other Injectors:
1. Ream the sleeves before installing the injectors. Ream only until the sleeves have been cut to provide a full length concentric taper past the injector/sleeve sealing interface.2. After reaming, apply a thin coating of liquid machinist's blue (Dykem) to the bottom of the sleeves - allow to dry. Install injector without

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