Information injection-pump assembly
ZEXEL
106674-4080
1066744080
MITSUBISHI-HEAV
3256532030
3256532030
Rating:
Service parts 106674-4080 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
32561-69010
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106674-4080
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106674-4080
1066744080
MITSUBISHI-HEAV
3256532030
3256532030
Zexel num
Bosch num
Firm num
Name
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-7420
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.9
3.85
3.95
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Opposite to the driving side NO.1
Opposite to the driving side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
15.4
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
428
419
437
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.3+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
27
24
30
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
20+1
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
354
304
404
Fixing the rack
*
Test data Ex:
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(20deg)
----------
----------
a=(20deg)
Information:
TECHNICAL INFORMATION BULLETIN July 7, 2004
Engines
Machines 3054E (304, CRX)
3056E (356, CPT)
315C (ANF)
320C (CCD)
924G (DDA, DFZ, RBB, WGX, WMB)
928G (DJD, WLG)
AP-655C (CDG)
CP-563E (BWE, CNT)
CP-573E (ASY)
CS-563E (ASA, CNG)
CS-583E (DAJ)
CS-663E (DAG)
IT28G (DBT, EWF, WAC)
M313C (BDR)
M315C (BDM)
M316C (BDX)
M318C (BCZ)
M322C (BDK)
TH330B (SLB)
Component Code 1251SUBJECT: Replace Failed 3054E and 3056E Fuel Injection Pumps with New Pumps from Cat Parts
PROBLEM:
The 3054E and 3056E engines use electronic Bosch fuel injection pumps. These are new engine applications for these pumps. Therefore, initially, Bosch is requesting that all failed pumps are to be replaced by new pumps from Cat Parts. Replaced pumps are to be returned to Bosch through Peoria, IL or Peterborough, U.K. as described below, depending on location.
SOLUTION:
Failed fuel injection pumps are to be replaced by new pumps out of Cat Parts. Pumps should only be replaced after a full diagnostic check of the Engine and Machine. Troubleshooting Guide, RENR2417, should be used in order to perform the full diagnostic check. Replaced pumps must be returned to Caterpillar Inc. for forwarding to the supplier for full failure analysis.
Pumps from NACD and LACD territories are to be packaged and shipped to:
Caterpillar Service Claims Room
8201 N. University
Peoria, IL 61615 USA
Attn: 3000 Series Engine Service Engineer
Pumps from EAME and APD territories are to be packaged and shipped to:
Perkins Engines Ltd.
Return Parts Centre-C/O Ron Chandler
Peterborough PE1 5NA
U.K.
All failure information is to be submitted with each pump. Dealers are requested to supply FULL details regarding their investigations into the failure of the pump. This information will allow for a more detailed analysis of the pump failure. Attach the normal service claim form. The following list represents the minimum amount of additional information that should be submitted with the faulty pump and the service claim form.
A breakdown of the fault finding process employed using RENR2417
Details of the failure including symptoms that were experienced (Hard to start, etc?)
Screen prints from Caterpillar Electronic Technician (Cat ET) describing both the logged and active fault codes at the time of investigation
Other relevant details from customers include engine and machine history and the usage at the time of the incident
Dealers from EAME should email the above information to Alex Radjenovic at Radjenovic_Alex@perkins.com
Dealers from NACD and LACD should email the above information to Robert Stoetzer at Stoetzer_Robert_A
All returned fuel injection pump ports must be sealed prior to shipment to prevent contamination. The protective caps used on the new pump ports MUST be transferred to the failed pump ports prior to return shipment to avoid contamination in route to the supplier. Also, it is imperative that the pump be protected against damage during transit. Damage during transit may prevent assessment by the supplier.
Dealers in the NACD territory are to follow the established parts return procedures per Service Warranty Bulletin No. 7.1.
Dealers outside of the NACD territory are required to pay for the shipping cost of the returned pump, then claim the shipping cost as a miscellaneous expense on the warranty claim.
COPYRIGHT 2004 CATERPILLAR
ALL RIGHTS RESERVED