Information injection-pump assembly
ZEXEL
108621-2050
1086212050
Rating:
Service parts 108621-2050 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
ME120897
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/24.5{250}
15.
NOZZLE SET
Include in #1:
108621-2050
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108621-2050
1086212050
Zexel num
Bosch num
Firm num
Name
108621-2050
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
131424-7220
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
RED3 control unit part number
407910-2
470
RED3 rack sensor specifications
mm
15
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
21
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
5.6
5.57
5.63
Beginning of injection position
Governor side NO.1
Governor 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
Rack position
(12.9)
Vist
V
1.42
1.42
1.42
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
148.5
147.5
149.5
Max. variation between cylinders
%
0
-2
2
Basic
*
PS407980-224*
V
V1+1.44+
-0.01
PS407980-224*
mm
3.2+-0.0
5
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_02
Rack position
(6.5)
Vist
V
2.7
2.6
2.8
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
10.5
8.5
12.5
Max. variation between cylinders
%
0
-15
15
PS407980-224*
V
V1+0.13+
-0.01
PS407980-224*
mm
5.4+-0.0
3
Governor adjustment
Pump speed
r/min
700--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
650
Advance angle
deg.
0.5
Governor adjustment_03
Pump speed
r/min
850
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
0000001201
Pre-stroke
mm
5.6
5.57
5.63
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
5
4.5
5.5
Remarks
When the eccentric pin is tightened
When the eccentric pin is tightened
_03
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1
0.95
1.05
Adjustment
*
Remarks
Output voltage V1
Output voltage V1
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.6
2.32
2.88
Output voltage
V
2.8
2.78
2.87
Confirmation
*
_05
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=16mm bb=1mm
----------
a=19deg+-5deg b=29deg+-5deg
----------
aa=16mm bb=1mm
----------
a=19deg+-5deg b=29deg+-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=5.6+-0.03mm
----------
a=(2deg)
----------
aa=5.6+-0.03mm
----------
a=(2deg)
0000001701
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 15 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
----------
----------
----------
----------
0000001901 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 (154610-0620)
(1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01.
(2)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)
----------
V1=1V
----------
----------
V1=1V
----------
Information:
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
There have been some isolated instances of issues with the Diesel Particulate Filter (DPF) on certain C3.4B engines.Solution
Caterpillar is aware of this problem. Follow the procedure that is detailed below.
Table 1
Required Tools
Tool Part Number Part Description Qty
A 233-7191 Hose Cleaner Gp 1
Obtain a fuel sample from the engine.
Obtain a lubricating oil sample from the engine.
Attach a copy of the full service history of the engine to the Service Information Systems (SIMSi) report. Include the change history of the following components:
Engine oil
Engine oil filter
Engine fuel filter
Crankcase breather filter
Ensure that the breather element is clean and free from wear or damage. Replace the breather element. Refer to Operation and Maintenance Manual, Engine Crankcase Breather Element - Replace for the correct procedure. Ensure that the inlet hose is clean and free from restriction. If the inlet hose requires replacing, refer to Disassembly and Assembly, Crankcase Breather - Install for the correct procedure.
Determine the service hours of the engine air cleaner element. Ensure that the engine air cleaner element is clean and free from wear, damage, or restriction. If necessary, replace the engine air cleaner element. Refer to Operation and Maintenance Manual, Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace for the correct procedure. Ensure that the hose assemblies are clean and free from restriction and dust.
Inspect the inlet and outlet hoses of the turbocharger for the presence of excessive lubricating oil. If necessary, take photographs inside both inlet and outlet hoses. If necessary, take photographs inside the compressor housing for the inlet and outlet. If excessive lubricating oil is found, replace the turbocharger. Refer to Disassembly and Assembly, Turbocharger
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
There have been some isolated instances of issues with the Diesel Particulate Filter (DPF) on certain C3.4B engines.Solution
Caterpillar is aware of this problem. Follow the procedure that is detailed below.
Table 1
Required Tools
Tool Part Number Part Description Qty
A 233-7191 Hose Cleaner Gp 1
Obtain a fuel sample from the engine.
Obtain a lubricating oil sample from the engine.
Attach a copy of the full service history of the engine to the Service Information Systems (SIMSi) report. Include the change history of the following components:
Engine oil
Engine oil filter
Engine fuel filter
Crankcase breather filter
Ensure that the breather element is clean and free from wear or damage. Replace the breather element. Refer to Operation and Maintenance Manual, Engine Crankcase Breather Element - Replace for the correct procedure. Ensure that the inlet hose is clean and free from restriction. If the inlet hose requires replacing, refer to Disassembly and Assembly, Crankcase Breather - Install for the correct procedure.
Determine the service hours of the engine air cleaner element. Ensure that the engine air cleaner element is clean and free from wear, damage, or restriction. If necessary, replace the engine air cleaner element. Refer to Operation and Maintenance Manual, Engine Air Cleaner Element (Single Element) - Inspect/Clean/Replace for the correct procedure. Ensure that the hose assemblies are clean and free from restriction and dust.
Inspect the inlet and outlet hoses of the turbocharger for the presence of excessive lubricating oil. If necessary, take photographs inside both inlet and outlet hoses. If necessary, take photographs inside the compressor housing for the inlet and outlet. If excessive lubricating oil is found, replace the turbocharger. Refer to Disassembly and Assembly, Turbocharger
Have questions with 108621-2050?
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Mitsubishi
Mitsubishi
Mitsubishi
Mitsubishi
Mitsubishi
108621-2050
INJECTION-PUMP ASSEMBLY