Information injection-pump assembly
BOSCH
9 400 611 353
9400611353
ZEXEL
107691-0154
1076910154
Rating:
Service parts 107691-0154 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
16600-Z5714
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/19.6{200}
14.
NOZZLE
Include in #1:
107691-0154
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 353
9400611353
ZEXEL
107691-0154
1076910154
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-4120
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
RED4 control unit part number
407915-0
590
RED4 rack sensor specifications
mm
19
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
14
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
1-4-2-6-
3-5
Pre-stroke
mm
5.1
5.07
5.13
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Rack position
(11.3)
PWM
%
51.5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
108
107
109
Max. variation between cylinders
%
0
-4
4
Basic
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Injection quantity adjustment_02
Rack position
(6.7)
PWM
%
25.6+-2.
8
Pump speed
r/min
445
445
445
Average injection quantity
mm3/st.
11
9.2
12.8
Max. variation between cylinders
%
0
-10
10
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5+-0.03
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Governor adjustment
Pump speed
r/min
1150--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
0.3
Governor adjustment_03
Pump speed
r/min
1250
Advance angle
deg.
2
1.2
2.8
Governor adjustment_04
Pump speed
r/min
(1300)
Advance angle
deg.
4
3.7
4.3
Remarks
Finish
Finish
0000001201
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2
1.95
2.05
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.1
5.07
5.13
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_03
CU407980-224*
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
Test data Ex:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=1mm bb=20mm
----------
a=20deg+-5deg b=37deg+-5deg
----------
aa=1mm bb=20mm
----------
a=20deg+-5deg b=37deg+-5deg
0000000901
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=5.1+-0.03mm
----------
a=(20deg)
----------
aa=5.1+-0.03mm
----------
a=(20deg)
Stop lever angle
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------
----------
----------
----------
0000001301
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001401
C:Shim
----------
----------
----------
----------
0000001501
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000001701
(PWM) Pulse width modulation (%)
(R) Rack position (mm)
Rack sensor output characteristics
1. Rack limit adjustment
(1)Measure the rack position R2 for PWM a2%.
(2)Confirm that it is within the range R2 = 15+-1 mm.
(3)Measure the rack position R1 at PWM a %.
(4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm.
2. Check the limp home operation.
(1)Move the switch box's limp home switch to the limp home side.
(2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table.
3. Check the pull down operation.
(1)Confirm that the rack position is 19 mm at PWM B%.
(2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5 % B=95%
----------
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5 % B=95%
----------
Information:
Features
Benefits
All critical engineering changes and updates included
Improved reliability and performance
Worldwide availability through Cat parts distribution system
Customer access regardless of location
Off-the-shelf availability
Downtime reduced through exchange product
Same-as-new Caterpillar warranty
Consistent support
Coverage Chart
Reman PN
New PN
Part Name
20R1298
3594090
INJECTOR GP - FUEL
20R1299
3494080
INJECTOR GP - FUEL
20R1301
3594020
INJECTOR GP - FUEL
20R1302
3594040
INJECTOR GP - FUEL
20R1303
3594070
INJECTOR GP - FUEL
20R1304
3597434
INJECTOR GP - FUEL
20R1308
3594050
INJECTOR GP - FUEL
20R1302
3594040
INJECTOR GP - FUEL
20R1317
3809889
INJECTOR GP - FUEL
20R1318
3674293
INJECTOR GP - FUEL
20R3247
3920225
INJECTOR GP - FUEL
20R3607
3820709
INJECTOR GP - FUEL
20R3608
3820745
INJECTOR GP – FUEL
20R3815
3689171
PUMP GP – FUEL INJ
20R3816
3689172
PUMP GP – FUEL INJ
20R3817
3689173
PUMP GP – FUEL INJ
Core Acceptance
The following Core Acceptance Criteria are available supporting these products. All the latest Core Acceptance Criteria guidelines can be found on the Reman Dealer Extranet at https://catreman.cat.com/cac
SELD0226 Unit Injectors Electronic
SELD0023 Fuel Pump & Governor Groups
Warranty
Please consult the appropriate warranty statement for your area by going to warranty.cat.com.
Core Management
Please refer to the Caterpillar Core Management Information System (CMIS 2) related to the parts information application that describes all Reman part/Core Acceptability Family (CAF) and other related information. Also, refer to other CMIS 2 inquiry applications such as: Dealer Customer Profile, Inspection Reason Codes, Inspection Line Inquiry, Dealer Add Charges, Dealer Entitlement Activity, Dealer CCR Inquiry, Dealer CCR Entry, Dealer Shipment Processing, Dealer Process Packaging Grief and Reporting. This information is available to all dealers worldwide that have been converted to CMIS 2.
Please go to the Reman web site https://catreman.cat.com for the latest policy and procedural updates that are available to all dealers worldwide explaining policy and procedural information such as “Policy and Core Management” -SELD0122; “Core Management Systems and Operations Procedures” -SELD0040; “Reman Core Return Packaging Instructions And Guidelines” -SELD0300; and “Shipping Instructions” SELD0039.
If you have any questions regarding Reman Core Management or Core Management Systems (CMIS2), feel free to call your Corinth Dealer Service Representative toll free at (800) 537-2928.
Contact Information:
For assistance with technical questions, call the Reman Technical Hot Line also toll free at (888) 88-REMAN or use our e-mail address--Reman_Help.
Global Dealer Solutions Network Parts Technical Support Team Toll Free -North America: 1-877-228-2420 International: +1-309-266-4421 Electronic Requests: Send via Microsoft Customer Relationship Management (MSCRM). For access and tutorial information: https://gdsn.cat.com/mscrm
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The information contained herein is intended for circulation only to Caterpillar and dealer employees whose duties require knowledge of such reports and is intended exclusively for their information and