Information injection-pump assembly
ZEXEL
108622-3350
1086223350
HINO
220008730A
220008730a
Rating:
Service parts 108622-3350 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
23600-2800B
12.
Open Pre:MPa(Kqf/cm2)
14.7{150}/21.6{220}
14.
NOZZLE
Include in #1:
108622-3350
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
108622-3350
1086223350
HINO
220008730A
220008730a
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
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
33
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
1-4-2-6-
3-5
Pre-stroke
mm
7.2
7.17
7.23
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
Adjusting point
-
Rack position
14.7
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
154
151
157
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4.8+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8.5+-0.5
Pump speed
r/min
380
380
380
Average injection quantity
mm3/st.
15
12
18
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
7.1+-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(14.7)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
154
152
156
Basic
*
Fixing the lever
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4.8+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.5
Pump speed
r/min
1075
1075
1075
Average injection quantity
mm3/st.
137.5
131.5
143.5
Fixing the lever
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4.8+-0.0
5
0000001601
Pre-stroke
mm
7.2
7.17
7.23
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
8.5
8
9
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
3.2
3.15
3.25
Output voltage
V
2.95
2.94
2.96
Adjustment
*
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
7.2
7.17
7.23
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
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)Set stop lever before governor adjustment. [When setting stop lever after governor adjustment, confirm that point B (Ra) can be obtained at full setting.]
(4)Stop lever's normal position setting: equivalent to RA
(5)Damper spring setting
(6)At half lever position
----------
T1=AD19 Ra=R1+0.5mm RA=18mm
----------
----------
T1=AD19 Ra=R1+0.5mm RA=18mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=34.5mm
----------
a=47.5deg+-5deg b=57deg+-5deg
----------
aa=34.5mm
----------
a=47.5deg+-5deg b=57deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa, rack position bb
(2)Set the stopper screw. (After setting, apply red paint.)
(3)Set the stopper screw at this lever angle.
(4)Use the hole above R = cc
----------
aa=0r/min bb=1.5+-0.3mm cc=30mm
----------
a=23deg+-5deg b=43deg+-5deg
----------
aa=0r/min bb=1.5+-0.3mm cc=30mm
----------
a=23deg+-5deg b=43deg+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=7.2+-0.03mm
----------
a=(1deg)
----------
aa=7.2+-0.03mm
----------
a=(1deg)
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 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.
----------
----------
----------
----------
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 limit adjustment
(1)Mount the joint (B).
(2)Select the shim (D) so that the rack limit's rack position is obtained at that time.
(3)Install the rod (E) to the block (C).
The distance between the pump end face and the rod (E) at rack limit must be L.
2. Rack sensor adjustment (-0020)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side.
(3)Set at speed N.
(4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.)
(5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(6)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)
----------
L=38-0.2mm N=1075r/min Ra=R1(14.7)+0.5mm
----------
----------
L=38-0.2mm N=1075r/min Ra=R1(14.7)+0.5mm
----------
Information:
Model Identification Number
773G JWS00162-00208
773G OEM T5T00101
775G MJS00273-00322
PARTS NEEDED
Qty
Part Number Description
2 1R1808 FILTER-LUBE
12 8S9191 BOLT
4 3460335 CLAMP-BAND
12 3594040 INJECTOR GP-FUEL
1 BULK_OIL DEO-ULS (95 Liters)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 4% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
If excessive fuel dilution of engine oil is found reference the following documents to determine the cause of fuel dilution.
Special Instruction, REHS3007,"Determining the Cause of Fuel Dilution of Engine Oil"
Troubleshooting, KENR9795, "C27 and C32 Engines for Caterpillar Built Machines"
Once an injector(s) has been identified as having a cracked/leaking injector body, replace the failed injector(s). Inspect the remaining good injector serial numbers with Cat ET, (Injector Serial Numbers = Injector trim file name, (ie 6Cxxxxxxxxxx.trm)). If the remaining injector serial numbers fall within the serial number range below, replace at the same time. Refer to Image 1 for the serial number
location on the top of the electronic unit injector.
Injector Serial Numbers
6C0018656646 through 6C0021994059
If an injector failure occurs on either of the rear two cylinders (right and/or left hand bank) the exhaust piping going from the turbo to the CEM will have to be removed. 346-0335 Exhaust Clamp cannot be reused and MUST be replaced with a new clamp. Refer to REHS5014, "Reuse Guideline for the Flexible Exhaust Pipe Group on Tier 4 Engines" for the proper installation and removal procedure. Refer to Image 2 for clamp location.
The 8S-9191 Injector Hold Down Bolts must be replaced.
Refer to Disassembly and Assembly, RENR9217 for the removal, installation, and tightening procedures.
After the engine is reassembled, change the engine oil and filters.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3500 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3501-6000 hrs,
25-48 mo 33.0% 50.0% 0.0% 0.0% 50.0% 50.0%
This is a 10.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.