Information injection-pump assembly
ZEXEL
108622-3651
1086223651
HINO
220009821A
220009821a
Rating:
Cross reference number
ZEXEL
108622-3651
1086223651
HINO
220009821A
220009821a
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
134424-1420
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
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.
33
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
(13.4)
Vist
V
1.32
1.32
1.32
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
184
182
186
Max. variation between cylinders
%
0
-2
2
Basic
*
PS407980-224*
V
2.2+-0.0
1
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_02
Rack position
(6.9)
Vist
V
2.6
2.5
2.7
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
17
14
20
Max. variation between cylinders
%
0
-15
15
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
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.
11.5
11
12
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
2.4
2.35
2.45
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
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
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=(50deg)
----------
aa=6.4+-0.03mm
----------
a=(50deg)
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.
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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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----------
----------
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Information:
If complete injector sets are replacedon 3412E machines:
PART Hours/Age, whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts (D/N) Labor Hrs (Cost) Parts Labor Hrs Parts (C/L) Labor Hrs (Sell)
0-4000 0-48 mos 100% 7 0 0 0 0
4001-8000 0-48 mos 33.3% 3.5 0 0 50% 3.5
* This is a 7-hour job. Actual hourspermitted up to maximums noted above.PARTS DISPOSITION
NACD Dealers, return Injector(s) to:Caterpillar Inc.Attn: Fergal O?Shea ? PS50424
Service Claims Room
8201 N. University
Peoria, IL 61615 ***** All Other Dealers *****
Handle the parts in accordance with yourWarranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
The two tests below provide the appropriateinjector troubleshooting and repair steps for injector updates.
Use "Test for Cylinder Cutout" to determine ifindividual injector replacements (using original injector part) are needed.
Use "Test for Leakage from Poppet Valve" to determineif full injector sets (using new injector parts and software change) areappropriate for repair.
Test for Cylinder Cutout:
Warm the engine out of Cold Mode.
Connect Caterpillar Electronic Technician (ET)to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm +/- 125rpm. An extremely rough running engine well need to be diagnosed by othermethods.
Cut out one bank of cylinders. Note engine rpmand the fuel position on the ET screen at that time.
Cut out one of the remaining cylinders from thecylinder bank that is running. Allow the engine to stabilize and note thefuel position.
Give power back to that cylinder. Allow the engineto stabilize and note the fuel position.
Repeat steps 5 through 6 until the cylinder bankhas been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps5 through 8.
Repeat steps 4 through 9 with the engine at 2000rpm.
Compare the results from the fuel position fromeach cylinder.
If the cylinder was cut out and the fuel positiondid not change, the cylinder may not have producing power. This cylinderwould be suspect.
When you are finished with the test, decreaseengine rpm to low idle and shut the engine off.
Replace any suspect injector with a similar originalinjector. Install new seals for the injector and the jumper tube duringthis repair. The injector repair procedure is found in Special InstructionREHS0116.
If this is the third injector failure,related to this Service Letter, and to the same engine serial number within120 calendar days, replace all the injectors and software following SpecialInstruction article REHS1385.It is also possible that multiple injectors arefunctioning improperly. Complete "Test for Leakage from Poppet Valve" inorder to evaluate potential excessive injector leakage and need for fuelsystem conversion.Test for Leakage from PoppetValve:
Warm engine out of Cold Mode to normal operatingtemperature.
Turn off the engine.
Remove the valve cover bolts in preparation toobserve the injectors. Leave covers in place.
: Hot oil and components can causepersonal injury. Do not allow hot oil or components to contact skin.
Restart the engine and run at low idle with noload.
Use the ET service tool in order to perform theoverride test for the injection actuation system. Increase injection actuationpressure to the maximum value.
Observe all of the injectors under each valvecover for leakage at the spill port. A small amount of dripping is acceptable.However, a continuous stream of oil is an indication of excessive leakageof the poppet valve. Only leaks at the spill port
PART Hours/Age, whichevercomes first Caterpillar Dealer Suggested Customer Suggested
Parts (D/N) Labor Hrs (Cost) Parts Labor Hrs Parts (C/L) Labor Hrs (Sell)
0-4000 0-48 mos 100% 7 0 0 0 0
4001-8000 0-48 mos 33.3% 3.5 0 0 50% 3.5
* This is a 7-hour job. Actual hourspermitted up to maximums noted above.PARTS DISPOSITION
NACD Dealers, return Injector(s) to:Caterpillar Inc.Attn: Fergal O?Shea ? PS50424
Service Claims Room
8201 N. University
Peoria, IL 61615 ***** All Other Dealers *****
Handle the parts in accordance with yourWarranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
The two tests below provide the appropriateinjector troubleshooting and repair steps for injector updates.
Use "Test for Cylinder Cutout" to determine ifindividual injector replacements (using original injector part) are needed.
Use "Test for Leakage from Poppet Valve" to determineif full injector sets (using new injector parts and software change) areappropriate for repair.
Test for Cylinder Cutout:
Warm the engine out of Cold Mode.
Connect Caterpillar Electronic Technician (ET)to the engine while the engine is running.
Ensure that the engine speed is 1200 rpm +/- 125rpm. An extremely rough running engine well need to be diagnosed by othermethods.
Cut out one bank of cylinders. Note engine rpmand the fuel position on the ET screen at that time.
Cut out one of the remaining cylinders from thecylinder bank that is running. Allow the engine to stabilize and note thefuel position.
Give power back to that cylinder. Allow the engineto stabilize and note the fuel position.
Repeat steps 5 through 6 until the cylinder bankhas been completely checked.
Power all cylinders. Allow the engine to stabilize.
Cut out the other cylinder bank and repeat steps5 through 8.
Repeat steps 4 through 9 with the engine at 2000rpm.
Compare the results from the fuel position fromeach cylinder.
If the cylinder was cut out and the fuel positiondid not change, the cylinder may not have producing power. This cylinderwould be suspect.
When you are finished with the test, decreaseengine rpm to low idle and shut the engine off.
Replace any suspect injector with a similar originalinjector. Install new seals for the injector and the jumper tube duringthis repair. The injector repair procedure is found in Special InstructionREHS0116.
If this is the third injector failure,related to this Service Letter, and to the same engine serial number within120 calendar days, replace all the injectors and software following SpecialInstruction article REHS1385.It is also possible that multiple injectors arefunctioning improperly. Complete "Test for Leakage from Poppet Valve" inorder to evaluate potential excessive injector leakage and need for fuelsystem conversion.Test for Leakage from PoppetValve:
Warm engine out of Cold Mode to normal operatingtemperature.
Turn off the engine.
Remove the valve cover bolts in preparation toobserve the injectors. Leave covers in place.
: Hot oil and components can causepersonal injury. Do not allow hot oil or components to contact skin.
Restart the engine and run at low idle with noload.
Use the ET service tool in order to perform theoverride test for the injection actuation system. Increase injection actuationpressure to the maximum value.
Observe all of the injectors under each valvecover for leakage at the spill port. A small amount of dripping is acceptable.However, a continuous stream of oil is an indication of excessive leakageof the poppet valve. Only leaks at the spill port