Information injection-pump assembly
ZEXEL
106861-2151
1068612151
Rating:
Cross reference number
ZEXEL
106861-2151
1068612151
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
131424-4620
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
A
Rack position
10.1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
155
152
158
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
66.7
66.7
Boost pressure
mmHg
500
500
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
145.5
141.5
149.5
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
C
Rack position
6.2+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
19.5
16.9
22.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
9.6
Boost pressure
kPa
42.7
41.4
44
Boost pressure
mmHg
320
310
330
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
(10.1)
Boost pressure
kPa
53.3
46.6
60
Boost pressure
mmHg
400
350
450
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
1.4
0.9
1.9
Timer adjustment_04
Pump speed
r/min
1100
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Deliver without the torque control spring operating.
(4)Supplied with torque spring not set.
(5)Boost compensator excessive fuel lever at operation: L1 (at 0 boost pressure)
(6)Main spring setting
(7)Set idle sub-spring
(8)Setting at shipping
----------
K=9 L1=12.7+-0.1mm
----------
----------
K=9 L1=12.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)At shipping
(2)Stopper bolt setting
----------
----------
a=12deg+-5deg b=28deg+-5deg c=(2deg)
----------
----------
a=12deg+-5deg b=28deg+-5deg c=(2deg)
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=19deg+-5deg b=46deg+-5deg
----------
----------
a=19deg+-5deg b=46deg+-5deg
0000001101
N:Normal
B:When boosted
(1)Rack position = aa at boost pressure 0.
----------
aa=12.7+-0.1mm
----------
a=(5deg) b=(15deg)
----------
aa=12.7+-0.1mm
----------
a=(5deg) b=(15deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
When reporting the repair, use "PS61391" as the Part Number and "7777" as the Group Number. Use "96" as Warranty Claim Description Code and use "Z" as the SIMS 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
30Jun2020
PROBLEM
The 398-1498 and 463-1678 Fuel Injection Pumps may fail on certain 320D 2 Excavators, equipped with C7.1M Engine. The fuel injection pump failure results in the engine not starting, hard to start, low power, or speed instability.
AFFECTED PRODUCT
Model Identification Number
320D 2 LCA01054-01108
TDZ00816-00829, 888-907, 911-923
PARTS NEEDED
Qty
Part Number Description
3 2323149 WASHER-SEALING
1 4631678 PUMP AS-F INJ
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
Refer REHS3767, Special Instruction, "Inspection of Fuel Injection Pumps on 3054C, C3.3, C4.4 (Mech), and C7.1 (Mech) Engines", to determine if the failure of fuel pump is caused by dirty fuel or customer's maintenance practices, and record facts as specified. Apply this Service Letter program only if the inspection reveals FIP failure that is not attributable to customer's maintenance or use of contaminated / bad fuel.
Remove the existing fuel injection pump, and install a new 463-1678 Fuel Injection Pump Assembly.
Refer to UENR0674, Disassembly and Assembly, C7.1 (Mech) Engines, "Fuel Injection Pump Remove - With Boost Control", and install procedure, in order to complete this Rework Procedure.
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,
0-24 mo 100.0% 0.0% 0.0% 100.0% 0.0% 0.0%
This is a 8.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.