Information injection-pump assembly
ZEXEL
106871-5470
1068715470
Rating:
Service parts 106871-5470 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-96514
12.
Open Pre:MPa(Kqf/cm2)
22.6{230}
15.
NOZZLE SET
Include in #1:
106871-5470
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-5470
1068715470
Zexel num
Bosch num
Firm num
Name
106871-5470
INJECTION-PUMP ASSEMBLY
14CD PE8P PE
14CD PE8P PE
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
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
1-8-7-5-
4-3-6-2
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5
Cal 1-8 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 1-5 deg. 135 134.5 135.5
Cal 1-5 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 1-3 deg. 225 224.5 225.5
Cal 1-3 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
Cyl.1-2 deg. 315 314.5 315.5
Cyl.1-2 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.7
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
126
125
127
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Solenoid boost comp. OFF
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
11.65
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
138
136
140
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Solenoid boost comp. OFF
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
6+-0.5
Pump speed
r/min
260
260
260
Average injection quantity
mm3/st.
14
12
16
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Solenoid boost comp. OFF
*
Injection quantity adjustment_04
Adjusting point
E
Rack position
R1(10.4)
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
109.5
107.5
111.5
Fixing the lever
*
Solenoid boost comp. ON
*
Timer adjustment
Pump speed
r/min
800--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
750
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
900
Remarks
Measure the actual advance angle.
Measure the actual advance angle.
Timer adjustment_04
Pump speed
r/min
1100
Advance angle
deg.
4.75
4.45
5.05
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Rack limit using stop lever: RA
(3)Damper spring setting: DL
(4)Rack difference between N = N1 and N = N2
(5)Variable speed specification: idling adjustment
(6)Fix the lever at the full-load position at delivery.
(7)Main spring setting
----------
RA=12.4+-0.1mm DL=5.5-0.2mm N1=1100r/min N2=600r/min
----------
----------
RA=12.4+-0.1mm DL=5.5-0.2mm N1=1100r/min N2=600r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Pump speed = aa
(2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=375r/min
----------
a=17deg+-5deg b=9deg+-5deg
----------
aa=375r/min
----------
a=17deg+-5deg b=9deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=30.5deg+-3deg
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=30.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Use the pin at R = bb
----------
aa=12.4+-0.1mm bb=46mm
----------
a=36deg+-5deg b=38deg+-5deg
----------
aa=12.4+-0.1mm bb=46mm
----------
a=36deg+-5deg b=38deg+-5deg
0000001501 BCS
(A) Screw for precise adjustment
(B) Pre-adjustment screw
(C) Control rack, rack decrease direction
(D) Rack limit
1. Solenoid boost compensator adjustment
(1)Supply DC: V1 to the solenoid terminals and confirm solenoid operation.
(2)With the solenoid ON, calculate L1 from the value of R1. [L1 = La - (10.5 - R1) +-0.2]
(3)Adjust (B) to obtain L1.
(4)Assemble the solenoid to the governor.
(5)With the solenoid ON, readjust (B) so that R1 is within the allowance a.
(6)With the solenoid OFF, perform all governor adjustments except rack limit adjustment.
(7)Set the pump speed at N1 and turn the solenoid ON.
(8)Adjust (A) so that R1 is within the allowance range a.
(9)Set the pump speed at N1 and fix the load lever in the full position
(10)Turn the solenoid switch ON and OFF several times and confirm that the difference in rack positions is within L2.
(11)Set the rack limit.
(12)Stamp the solenoid valve.
----------
V1=24V N1=400r/min N2=0r/min R1=10.4mm a=+-0.5mm La=31mm L1=(30.9)+-0.2mm L2=3.5~5mm
----------
----------
V1=24V N1=400r/min N2=0r/min R1=10.4mm a=+-0.5mm La=31mm L1=(30.9)+-0.2mm L2=3.5~5mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder.
(3)-
(4)-
----------
----------
a=(90deg)
----------
----------
a=(90deg)
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.
This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS8088" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the January 25, 1994 (Revised December 1994) Service Letter. Changes have been made to the Parts Stock Action.
Termination Date
January 31, 1996Problem
The fuel nozzles used on certain 3208 Engines may crack at the braze joint.
Affected Product
Model & Identification Number
3208 ( 30A5540-5956 (Arrangements 9Y8574, 9Y8575, 1228675, 1228676, 1228679, 1228680); 62W74820-80012 (Arrangements 0R0776, 0R0975, 0R0976, 0R2818, 0R2819, 0R2875, 0R3231); 5YF1531-2058 (Arrangements 4P2649, 4P3027, 9Y2229, 9Y3136, 1042666, 1061496, 1077956, 1077957); 01Z26425-28100 (Arrangements 2W1320, 2W1325, 7W7500, 7W9150, 1013714, 1176582); 03Z11912-13004 (Arrangements 4P1724, 1067075, 1108885, 1168163, 1168164, 1168165, 1214692); 51Z81870-82239 (Arrangements 4P0921, 4P0922, 111364); 93Z8798-11332 (Arrangement 0R1098); 99R1533-1541 (Arrangement 5R6639); 79V24858 (Arrangement 1W0331))
Parts Needed
1 - 0R2503 Nozzle Assembly (Reman Equivalent of 1W5829)*1 - 0R2821 Nozzle Assembly (Reman Equivalent of 7W3710)*1 - 0R3284 Nozzle Assembly (Reman Equivalent of 4W8483)*1 - 1153354 Nozzle Assembly (No Reman Equivalent)**Use as requiredAction Required
Parts Stock
Remove all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies from Parts Stock with date codes of D--3, E--3, F--3, G--3, H--3, J--3, K--3, L--3, M--3, A--4, B--4, C--4, D--4, E--4, or F--4. Date codes are located on the nozzle assembly as shown below:
Location of Date CodeAffected Product
Remove all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies with date codes of D--3, E--3, F--3, G--3, H--3, J--3, K--3, L--3, M--3, A--4, B--4, C--4, D--4, E--4, or F--4 from the engine and replace with new nozzle assemblies or the remanufactured equivalent nozzle assemblies.
Service Claim Allowances
Parts Stock
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
Affected Product
Industrial and Marine Engines Up to 6-hours labor may be claimed.
Truck Engines Claim labor hours in accordance with TRG book.
Parts Disposition
U.S. and Canadian Dealers
Return all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn:Howard Jenkel
Service Claims Room
8201 N. University
Peoria, IL 61615
For remanufactured nozzle assemblies 0R2503, 0R2821, and 0R3284, include a copy of the "Core Credit Request Packing List".
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS8088" as the Part Number and "7755" as the Group Number. If administered before failure, use "56" as the Warranty Claim Description Code and use "T" as the SIMS Description Code. If administered after failure, use "96" as the Warranty Claim Description Code and use "Z" as the SIMS Description Code.
This Revised Service Letter replaces the January 25, 1994 (Revised December 1994) Service Letter. Changes have been made to the Parts Stock Action.
Termination Date
January 31, 1996Problem
The fuel nozzles used on certain 3208 Engines may crack at the braze joint.
Affected Product
Model & Identification Number
3208 ( 30A5540-5956 (Arrangements 9Y8574, 9Y8575, 1228675, 1228676, 1228679, 1228680); 62W74820-80012 (Arrangements 0R0776, 0R0975, 0R0976, 0R2818, 0R2819, 0R2875, 0R3231); 5YF1531-2058 (Arrangements 4P2649, 4P3027, 9Y2229, 9Y3136, 1042666, 1061496, 1077956, 1077957); 01Z26425-28100 (Arrangements 2W1320, 2W1325, 7W7500, 7W9150, 1013714, 1176582); 03Z11912-13004 (Arrangements 4P1724, 1067075, 1108885, 1168163, 1168164, 1168165, 1214692); 51Z81870-82239 (Arrangements 4P0921, 4P0922, 111364); 93Z8798-11332 (Arrangement 0R1098); 99R1533-1541 (Arrangement 5R6639); 79V24858 (Arrangement 1W0331))
Parts Needed
1 - 0R2503 Nozzle Assembly (Reman Equivalent of 1W5829)*1 - 0R2821 Nozzle Assembly (Reman Equivalent of 7W3710)*1 - 0R3284 Nozzle Assembly (Reman Equivalent of 4W8483)*1 - 1153354 Nozzle Assembly (No Reman Equivalent)**Use as requiredAction Required
Parts Stock
Remove all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies from Parts Stock with date codes of D--3, E--3, F--3, G--3, H--3, J--3, K--3, L--3, M--3, A--4, B--4, C--4, D--4, E--4, or F--4. Date codes are located on the nozzle assembly as shown below:
Location of Date CodeAffected Product
Remove all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies with date codes of D--3, E--3, F--3, G--3, H--3, J--3, K--3, L--3, M--3, A--4, B--4, C--4, D--4, E--4, or F--4 from the engine and replace with new nozzle assemblies or the remanufactured equivalent nozzle assemblies.
Service Claim Allowances
Parts Stock
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
Affected Product
Industrial and Marine Engines Up to 6-hours labor may be claimed.
Truck Engines Claim labor hours in accordance with TRG book.
Parts Disposition
U.S. and Canadian Dealers
Return all 0R2503, 0R2821, 0R3284, 1W5829, 4W8483, 7W3710, and 1153354 Nozzle Assemblies that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn:Howard Jenkel
Service Claims Room
8201 N. University
Peoria, IL 61615
For remanufactured nozzle assemblies 0R2503, 0R2821, and 0R3284, include a copy of the "Core Credit Request Packing List".
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Have questions with 106871-5470?
Group cross 106871-5470 ZEXEL
Nissan-Diesel
Nissan-Diesel
Nissan-Diesel
Nissan-Diesel
Nissan-Diesel
Nissan-Diesel
106871-5470
INJECTION-PUMP ASSEMBLY