108922-1080 ZEXEL 9 400 611 305 BOSCH INJECTION-PUMP ASSEMBLY 9400611305 1089221080

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 305 9400611305

ZEXEL 108922-1080 1089221080

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Buy INJECTION-PUMP ASSEMBLY 108922-1080 zexel genuine, new aftermarket engine parts with delivery

Service parts 108922-1080 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108092-0220

3. GOVERNOR 105960-0190

4. SUPPLY PUMP 105237-0210

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0860

7. COUPLING PLATE

8. _ 159640-0321

9. _ 156640-1921

10. NOZZLE AND HOLDER ASSY 105110-7830

11. Nozzle and Holder 1-15300-345-0

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/22.1{225}

13. NOZZLE-HOLDER 105041-4270

14. NOZZLE

15. NOZZLE SET 105019-2330

Include in #1:

108922-1080 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 305 9400611305

ZEXEL 108922-1080 1089221080

Zexel num

Bosch num

Firm num

Name

108922-1080
108922-1081

9 400 611 305

INJECTION-PUMP ASSEMBLY
* K

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 131424-8120

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

RED4 control unit part number 407915-0 590

RED4 rack sensor specifications mm 19

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 51

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-7-6- 5-4-3-10 -9-2

Pre-stroke mm 7.2 7.17 7.23

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 32 31.75 32.25

Difference between angles 2
Cal 1-7 deg. 72 71.75 72.25

Difference between angles 3
Cal 1-6 deg. 104 103.75 104.25

Difference between angles 4
Cal 1-5 deg. 144 143.75 144.25

Difference between angles 5
Cal 1-4 deg. 176 175.75 176.25

Difference between angles 6
Cal 1-3 deg. 216 215.75 216.25

Difference between angles 7
Cal 1-10 deg. 248 247.75 248.25

Difference between angles 8
Cal 1-9 deg. 288 287.75 288.25

Difference between angles 9
Cyl.1-2 deg. 320 319.75 320.25

Injection quantity adjustment

Rack position (12.2)

PWM % 57

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 158.5 156.5 160.5

Max. variation between cylinders % 0 -3 3

Basic *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4.8+-0.0 5

Injection quantity adjustment_02

Rack position (6.5)

PWM % 24.7+-2. 8

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 16.5 13.3 19.7

Max. variation between cylinders % 0 -13 13

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 7.1+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

0000001201

Pre-stroke mm 7.2 7.17 7.23

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 11.5 11 12

Remarks
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

_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=20mm bb=1mm
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a=37deg+-5deg b=37deg+-5deg

0000000901

(1)Pump vertical direction (2)Position of coupling's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=1deg bb=7.2+-0.03mm
----------
a=(90deg)

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.
----------

----------

0000001701

(PWM) Pulse width modulation (%) (R) Rack position (mm) Rack sensor output characteristics 1. Rack limit adjustment (1)Measure the rack position R2 for PWM a2%. (2)Confirm that it is within the range R2 = 15+-1 mm. (3)Measure the rack position R1 at PWM a %. (4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm. 2. Check the limp home operation. (1)Move the switch box's limp home switch to the limp home side. (2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table. 3. Check the pull down operation. (1)Confirm that the rack position is 19 mm at PWM B%. (2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25 % a2=72.5 % L1=1-- mm L2=19++mm A=5 % B=95 %
----------

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.
COMPLETION DATE
TERMINATION DATE
28Feb2007 31Aug2007
PROBLEM
The torque on the 100-6920 Direct Injection Fuel Nozzle Adapters may be out of specification.
AFFECTED PRODUCT
Model Identification Number
3408C TAM00350-00351
3412 38S24043
BCS02130
3412C 9BR03238
9EP03871, 3969-3970, 3972-3973
DJN01044-01070, 1074-1076, 1081, 1087
RLR00339, 341-342
TFT00565-00583
PARTS NEEDED
No parts needed for this program
ACTION REQUIRED
Remove valve covers, fuel lines and fuel nozzles. Tighten the 100-6920 Direct Injection Fuel Nozzle Adapters to 200 +/- 14 Nm (150 +/- 10 lb ft). Reassemble engine. For detailed instructions, refer to the procedure in the Disassembly and Assembly manual. Test engine for proper operation after reassembly.
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.
SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 3.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR TIGHTENING THE DIRECT INJECTION FUEL NOZZLE ADAPTERS
MODELS INVOLVED - Certain 3408 and 3412 Engines
Dear Caterpillar Product Owner:
The torque on the Direct Injection Fuel Nozzle Adapters may be out of specification. The Direct Injection Fuel Nozzle Adapters need to be tightened to the correct torque on the products listed below. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
Please refer the dealer to their Service Letter dated 24Aug2006 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 24Aug2006 Service Letter