Information injection-pump assembly
ZEXEL
106861-2000
1068612000
Rating:
Service parts 106861-2000 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME066034
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106861-2000
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106861-2000
1068612000
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
105780-8140
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-2-7-3-
4-5-6-8
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
9.2
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
134
130
138
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
D
Rack position
6.2+-0.5
Pump speed
r/min
200
200
200
Each cylinder's injection qty
mm3/st.
18.5
15.7
21.3
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(9.2)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
134
133
135
Fixing the lever
*
Boost pressure
kPa
40
40
Boost pressure
mmHg
300
300
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(9.2)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
141
135.4
146.6
Difference in delivery
mm3/st.
11.2
11.2
11.2
Fixing the lever
*
Boost pressure
kPa
40
40
Boost pressure
mmHg
300
300
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(8.9)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
120
116
124
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
E
Rack position
9.9+-0.5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
110
90
130
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R2(8.9)
Boost pressure
kPa
22
20.7
23.3
Boost pressure
mmHg
165
155
175
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(9.2)
Boost pressure
kPa
30
23.3
36.7
Boost pressure
mmHg
235
185
285
Timer adjustment
Pump speed
r/min
850+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.9
0.4
1.4
Timer adjustment_03
Pump speed
r/min
1000
Advance angle
deg.
23
22.5
23.5
Timer adjustment_04
Pump speed
r/min
1150
Advance angle
deg.
5.5
5
6
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
----------
DL=5.4-0.2mm
----------
----------
DL=5.4-0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=18deg+-5deg
----------
----------
a=18deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=21.5deg+-3deg
----------
----------
a=10deg+-5deg b=21.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=10deg+-5deg b=64deg+-5deg
----------
----------
a=10deg+-5deg b=64deg+-5deg
0000001501 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325+-5r/min Ra=5.9mm
----------
----------
N1=325+-5r/min Ra=5.9mm
----------
Information:
04Feb2016
U-58
A-46
D-55
O-52
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR REMOVING 398-1498 AND 463-1678 FUEL INJECTION PUMPS FROM DEALER PARTS STOCK
7750 PI70604
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the 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
31May2016
PROBLEM
The existing 398-1498 and 463-1678 Fuel Injection Pumps can fail. Fuel Injection Pumps up to and inclusive of component serial number 06369GJG, are suspect.
ACTION REQUIRED
Inspect all 398-1498 and 463-1678 Fuel Injection Pumps in dealer parts stock. Review the component serial number on each 398-1498 and 463-1678 Fuel Injection Pump. The Fuel Injection Pump component serial number can be located on the Fuel Injection Pump data plate, affixed to the side of the Fuel Injection Pump body.
The Fuel Injection Pump component serial number is alphanumeric, Refer to Image 1 for explanation on component serial number translation. In the given example the date code would translate to the following - 6369th pump built in July 2015.
NOTE - The build facility is not applicable in determining if the Fuel Injection Pump is suspect or not.
Refer to Image 2 for the build month and build year translation table.
Please action according to the following build month and build year color code -
Red = Remove from dealer part stock
Orange = Check Fuel Injection Pump Serial Number (06369 and below = Remove from dealer part stock / 06370 and Up = Return to dealer part stock).
Green = OK, Return to dealer part stock.
- If the Fuel Injection Pump is removed from dealer parts stock. Refer to the Service Claim Allowances and Parts Disposition.
- If the Fuel Injection Pump is returned to dealer parts stock, mark the box as inspected.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Submit one claim for all Fuel Injection Pumps removed from dealer parts stock. Include the date code (e.g. 06369GJG) in the claim story for each Fuel Injection Pump removed from dealer parts stock.
PARTS DISPOSITION
NACD:
Hold all 398-1498 and 463-1678 Fuel Injection Pumps removed from dealer parts stock for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing