Information injection-pump assembly
ZEXEL
108622-3101
1086223101
HINO
220007563A
220007563a
Rating:
Service parts 108622-3101 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
23600-2391B
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/27.5{280}
14.
NOZZLE
Include in #1:
108622-3101
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108622-3101
1086223101
HINO
220007563A
220007563a
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
134424-1520
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
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)
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
6.4
6.37
6.43
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
(11.8)
Vist
V
1.64
1.64
1.64
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
172.8
170.8
174.8
Max. variation between cylinders
%
0
-2
2
Basic
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_02
Rack position
(6.3)
Vist
V
2.7
2.6
2.8
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
11.6
8.6
14.6
Max. variation between cylinders
%
0
-15
15
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
0000001201
Pre-stroke
mm
6.4
6.37
6.43
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
4
3.95
4.05
Output voltage
V
2.62
2.61
2.63
Adjustment
*
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
6.4
6.37
6.43
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_05
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
3.4
Output voltage
V
3
2.98
3
Confirmation
*
_06
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=13.6+-0.2mm
----------
a=10deg+-5deg b=24deg+-5deg
----------
aa=1mm bb=13.6+-0.2mm
----------
a=10deg+-5deg b=24deg+-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=6.4+-0.03mm
----------
a=(40deg)
----------
aa=6.4+-0.03mm
----------
a=(40deg)
0000001501
(A): Pre-stroke actuator
(B): Stamp housings A and B at the same time.
(C): Stamping range
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 the counterclockwise 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.
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----------
----------
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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.
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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.
If the work described in this Program was performed on the Affected Product under PI7298, Service Letter dated October 30, 1992, DO NOT repeat the work.
This Revised Service Letter replaces the April 28, 1993 Service Letter revised March 1994. Changes have been made to the TERMINATION DATE and Affected Product.
Termination Date
August 31, 1994Problem
The fuel injection pumps used on certain Remanufactured 1160 and 3208 Engines need to be inspected for gummy deposits.
Affected Product
Model & Identification Number
1160 (57V1-34485)
3208 (9WC1-1093)
3208 (5CD1-9736, 62W1-76455 , 93Z1-10198 )
Parts Stock Remanufactured Fuel Pump Part Numbers
This program applies only to pumps in parts stock with a date code prior to November, 1993 (UUDE). Date codes are in the MM/YY mode with the standard notation of NUMERALKOD.
Parts Needed
Not applicable.
Action Required
Before installing or delivering any of the Affected Product, perform the following steps to ensure the internal fuel injection pump components are not stuck due to fuel pump gumming:
1. Remove the top cover of the fuel injection pump and check to ensure that all sleeves and levers are free and there are no gummy deposits on any of these components.2. If inspection performed in Step 1 indicates everything is clean, install top cover and return to parts stock.3. If inspection reveals components have gummy deposits, remove 12 ounces of fuel from the fuel pump housing and replace it with:- Fuel Injector Cleaneror- Carburetor/Choke Cleaner4. Allow the components to soak in cleaning solution for 45 minutes. Then, rotate the engine crankshaft to rotate the fuel injection pump and check for free movement of the lever and sleeve (on pumps only, rotate the fuel pump camshaft). This will ensure the components have the gummy deposits removed.5. If the above procedures do not free the pump assembly, remove the individual pumps from the pump housing, clean them with cleaning solution, and install them back into the housing.6. If the engine or fuel pump will be used immediately, install the cover on the fuel injection pump, and install or deliver the engine or pump.7. If the engine or fuel pump will be returned to stock, DO NOT leave the fuel injection pump full of cleaning solution because it may not contain any rust inhibitors. Remove the cleaning solution, fill the fuel injector pump with clean diesel fuel, and install the cover on the pump.Service Claim Allowances
The inspection of the pump is a .5-hour job. If the pump needs to be cleaned, an additional .5 hour may be claimed. If the individual pumps need to be removed from the pump housing for cleaning, up to an additional 1.5 hours may be claimed.
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
If the work described in this Program was performed on the Affected Product under PI7298, Service Letter dated October 30, 1992, DO NOT repeat the work.
This Revised Service Letter replaces the April 28, 1993 Service Letter revised March 1994. Changes have been made to the TERMINATION DATE and Affected Product.
Termination Date
August 31, 1994Problem
The fuel injection pumps used on certain Remanufactured 1160 and 3208 Engines need to be inspected for gummy deposits.
Affected Product
Model & Identification Number
1160 (57V1-34485)
3208 (9WC1-1093)
3208 (5CD1-9736, 62W1-76455 , 93Z1-10198 )
Parts Stock Remanufactured Fuel Pump Part Numbers
This program applies only to pumps in parts stock with a date code prior to November, 1993 (UUDE). Date codes are in the MM/YY mode with the standard notation of NUMERALKOD.
Parts Needed
Not applicable.
Action Required
Before installing or delivering any of the Affected Product, perform the following steps to ensure the internal fuel injection pump components are not stuck due to fuel pump gumming:
1. Remove the top cover of the fuel injection pump and check to ensure that all sleeves and levers are free and there are no gummy deposits on any of these components.2. If inspection performed in Step 1 indicates everything is clean, install top cover and return to parts stock.3. If inspection reveals components have gummy deposits, remove 12 ounces of fuel from the fuel pump housing and replace it with:- Fuel Injector Cleaneror- Carburetor/Choke Cleaner4. Allow the components to soak in cleaning solution for 45 minutes. Then, rotate the engine crankshaft to rotate the fuel injection pump and check for free movement of the lever and sleeve (on pumps only, rotate the fuel pump camshaft). This will ensure the components have the gummy deposits removed.5. If the above procedures do not free the pump assembly, remove the individual pumps from the pump housing, clean them with cleaning solution, and install them back into the housing.6. If the engine or fuel pump will be used immediately, install the cover on the fuel injection pump, and install or deliver the engine or pump.7. If the engine or fuel pump will be returned to stock, DO NOT leave the fuel injection pump full of cleaning solution because it may not contain any rust inhibitors. Remove the cleaning solution, fill the fuel injector pump with clean diesel fuel, and install the cover on the pump.Service Claim Allowances
The inspection of the pump is a .5-hour job. If the pump needs to be cleaned, an additional .5 hour may be claimed. If the individual pumps need to be removed from the pump housing for cleaning, up to an additional 1.5 hours may be claimed.
US and Canadian Dealers Only - When submitting a Parts Stock claim use 99Z00007 in the Product Identification Number Field.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.