Information injection-pump assembly
ZEXEL
107691-2222
1076912222
Rating:
Cross reference number
ZEXEL
107691-2222
1076912222
Zexel num
Bosch num
Firm num
Name
107691-2222
INJECTION-PUMP ASSEMBLY
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
131425-0520
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
PS/ACT control unit part no.
407910-3
03*
Selector switch no.
01
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
15
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
1-5-3-6-
2-4
Pre-stroke
mm
5.6
5.57
5.63
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 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
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
10.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
87.5
85.9
89.1
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
7.8+-0.5
Pump speed
r/min
485
485
485
Average injection quantity
mm3/st.
16
14.5
17.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5.5+-0.0
3
PS407910-303*
V
V1+0.05+
-0.01
PS407910-303*
mm
5.5+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.8)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
87.5
86.5
88.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
27.3
27.3
Boost pressure
mmHg
205
205
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.4
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
98.5
94.5
102.5
Fixing the lever
*
Boost pressure
kPa
27.3
27.3
Boost pressure
mmHg
205
205
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
5
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R2-0.2
Boost pressure
kPa
9.3
8
10.6
Boost pressure
mmHg
70
60
80
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R2(R1-1.
2)
Boost pressure
kPa
14
14
14
Boost pressure
mmHg
105
105
105
Timer adjustment
Pump speed
r/min
(N1+50)-
-
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
N1
Advance angle
deg.
0
-0.5
0
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
-1.3
-1.8
-0.8
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
0000001601
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_03
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
_04
CU407910-303*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_05
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_06
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
----------
T1=L06 BCL=0.2+-0.1mm
----------
----------
T1=L06 BCL=0.2+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=24deg+-5deg b=(40deg)+-3deg
----------
----------
a=24deg+-5deg b=(40deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)At speed = bb and rack position = cc, confirm that the stopper bolt is set at the non-injection position.
(3)After setting the stopper bolt, confirm non-injection at speed dd.
----------
aa=40mm bb=1845r/min cc=1-0.5mm dd=335r/min
----------
a=15deg+-5deg b=(45deg)+-5deg
----------
aa=40mm bb=1845r/min cc=1-0.5mm dd=335r/min
----------
a=15deg+-5deg b=(45deg)+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)Pre-stroke: bb
----------
aa=6deg bb=5.6+-0.03mm
----------
a=(8deg)
----------
aa=6deg bb=5.6+-0.03mm
----------
a=(8deg)
0000001401
(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.
----------
----------
----------
----------
0000001701
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001801
C:Shim
----------
----------
----------
----------
0000001901
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 clockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in a counter clockwise direction when viewed from the drive side and adjust so that the adjustment point becomes the adjustment value, then fully tighten.
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.
----------
----------
----------
----------
0000002201 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1450r/min Ra=R1(10.8)+1.4mm
----------
----------
N1=1450r/min Ra=R1(10.8)+1.4mm
----------
0000002301 SPEED SENSOR
(A) Flyweight projection
(B) Pickup sensor
(c) Lock nut
Speed sensor installation
(1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L.
(This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------
----------
L=0.8~1mm
----------
Information:
Caterpillar: Confidential Yellow
OPTIONAL:IMPROVED FUEL TRANSFER PUMP SEALS FOR COLD WEATHER OPERATION; CHECK FOR NOZZLE GAS LEAKAGE - 3406B IN ALL APP LICATIONS - PI7090 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, TRUCK, MARINE & AGRICULTURE TEPS
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.
IMPROVED FUEL TRANSFER PUMP VALVES FOR COLD WEATHER OPERATION; CHECK FOR NOZZLE GAS LEAKAGE, 3406B Truck, Marine, And Industrial Engines; 3406B Generator Sets; 16G Motor Graders; 245 Excavators And Front Shovels; 824C Tractors; 825C, 826C Compactors; 980C Loaders, 1254, 1256, 1250, PI7090 U-56 A-36 AU-47 B-21 C-51 E-34 O-42 TT-3 TA-3 TM-4 optional parts stock action needed If you received the January 6, 1984 Safety Service Letter (PI1019) and/or the December 2, 1983 Service Letter (PI7049), do all three PIP's at the same time. Problems ****Transfer Pump Valves**** The fuel transfer pump on the above engines has three 1W6182 Valve Assemblies. The one valve in the piston can break in extremely cold weather due to excessive restriction from jelled fuel. Some damage can also occur to the other valve assemblies. A new valve with less flow restriction is now used in the piston and at the other two locations in the pump. These valves are directly adaptable to earlier engines. ****Combustion Gas Leakage Around Fuel Nozzles**** There is a possibility that combustion gases can escape by a fuel injection nozzle and into the adapter. The high temperatures soften the end of the nozzle body and cause the tip to come off. The usual cause for escaping combustion gases is either a loose nozzle in the adapter or a cut in the carbon dam (gas seal). See Illustration 1. Nozzle hold down clamps are all now tightened properly, and an improved chamfer is machined inside the bottom of the adapters to prevent cutting the carbon dam. ILLUSTRATION 1 (SEE ILLUSTRATION) Affected Models And Parts Needed Some of the following vehicles contain the 3406 Engine with the former scroll fuel system and are not in this Program. PIN's (Product Identification No.) Or Serial No. Model Both Problems Gas Leakage Only 3406B Truck Engine 7FB1-8348 8349 - 10145 3406B Marine Engine 4TB1-383 384 - 396 3406B Industrial Engine 6TB1-1184 1185 - 1276 3406B Generator Set 2WB1-1044 1045 - 1166 16G Motor Grader 93U2284-93U2417 93U2418-93U2432 245 Excavator 95V1084-95V1111 95V1112-95V1116 245 Excavator
OPTIONAL:IMPROVED FUEL TRANSFER PUMP SEALS FOR COLD WEATHER OPERATION; CHECK FOR NOZZLE GAS LEAKAGE - 3406B IN ALL APP LICATIONS - PI7090 - MAILED US AND CANADA, CACO, COFA, BRAZIL, CFEL, COSA, TRUCK, MARINE & AGRICULTURE TEPS
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.
IMPROVED FUEL TRANSFER PUMP VALVES FOR COLD WEATHER OPERATION; CHECK FOR NOZZLE GAS LEAKAGE, 3406B Truck, Marine, And Industrial Engines; 3406B Generator Sets; 16G Motor Graders; 245 Excavators And Front Shovels; 824C Tractors; 825C, 826C Compactors; 980C Loaders, 1254, 1256, 1250, PI7090 U-56 A-36 AU-47 B-21 C-51 E-34 O-42 TT-3 TA-3 TM-4 optional parts stock action needed If you received the January 6, 1984 Safety Service Letter (PI1019) and/or the December 2, 1983 Service Letter (PI7049), do all three PIP's at the same time. Problems ****Transfer Pump Valves**** The fuel transfer pump on the above engines has three 1W6182 Valve Assemblies. The one valve in the piston can break in extremely cold weather due to excessive restriction from jelled fuel. Some damage can also occur to the other valve assemblies. A new valve with less flow restriction is now used in the piston and at the other two locations in the pump. These valves are directly adaptable to earlier engines. ****Combustion Gas Leakage Around Fuel Nozzles**** There is a possibility that combustion gases can escape by a fuel injection nozzle and into the adapter. The high temperatures soften the end of the nozzle body and cause the tip to come off. The usual cause for escaping combustion gases is either a loose nozzle in the adapter or a cut in the carbon dam (gas seal). See Illustration 1. Nozzle hold down clamps are all now tightened properly, and an improved chamfer is machined inside the bottom of the adapters to prevent cutting the carbon dam. ILLUSTRATION 1 (SEE ILLUSTRATION) Affected Models And Parts Needed Some of the following vehicles contain the 3406 Engine with the former scroll fuel system and are not in this Program. PIN's (Product Identification No.) Or Serial No. Model Both Problems Gas Leakage Only 3406B Truck Engine 7FB1-8348 8349 - 10145 3406B Marine Engine 4TB1-383 384 - 396 3406B Industrial Engine 6TB1-1184 1185 - 1276 3406B Generator Set 2WB1-1044 1045 - 1166 16G Motor Grader 93U2284-93U2417 93U2418-93U2432 245 Excavator 95V1084-95V1111 95V1112-95V1116 245 Excavator
Have questions with 107691-2222?
Group cross 107691-2222 ZEXEL
107691-2222
INJECTION-PUMP ASSEMBLY