Information injection-pump assembly
ZEXEL
101492-9230
1014929230
MITSUBISHI-HEAV
3676112020
3676112020
Rating:
Service parts 101492-9230 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
36761-05081
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}
15.
NOZZLE SET
Cross reference number
ZEXEL
101492-9230
1014929230
MITSUBISHI-HEAV
3676112020
3676112020
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 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
134424-0920
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
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
1-3-4-2
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
8.6
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
38.5
37.5
39.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.8+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
9.2
7.9
10.5
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)Set idle sub-spring
(4)Main spring setting
(5)Rack difference between N = N1 and N = N2
----------
K=10 RAL=11.8+-0.2mm N1=1250r/min N2=700r/min
----------
----------
K=10 RAL=11.8+-0.2mm N1=1250r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(13deg)+-5deg b=(22deg)+-5deg
----------
----------
a=(13deg)+-5deg b=(22deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=72deg+-5deg b=53deg+-5deg
----------
----------
a=72deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of key groove at No 1 cylinder's beginning of injection
(3)Stamp aligning marks on the pump housing flange.
(4)-
----------
----------
a=58deg+-3deg b=4deg+-30min
----------
----------
a=58deg+-3deg b=4deg+-30min
Information:
PARTS NEEDED
Qty
Part Number Description
*******Group 1*******
1 4947040 SFWR GP-A1000
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 17% 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.
*******Group 2*******
1 5011552 SFWR GP-A1000
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 17% 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
Before failure:
Flash the latest DEF Software onto the DEF Pump with the software listed in Parts Needed or latest available in SIS Web.
For flash programming of the ECM software, refer to Troubleshooting "ECM Software - Install".
After Failure:
Flash the latest DEF Software onto the DEF Pump with the software listed in Parts Needed or latest available in SIS Web.
For flash programming of the ECM software, refer to Troubleshooting "ECM Software - Install".
Remove the DEF Injector. Refer to Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install".
Follow rework procedure below for cleaning of the DEF Injector.
1. Stand the injector in suitable non metallic container. Fill the container with deionized water. Ensure the level does not exceed, as illustrated in Image 1.
2. Leave injector in the container for 20 minutes, check every 5 minutes to confirm any deposits have been dissolved.
3. Remove injector from container.
Install the DEF Injector. Refer to Disassembly and Assembly, "DEF Injector and Mounting - Remove and Install".
Image1
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 1*******
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 0.5-hour job for Group 1
For After failure, and additional 3 hours are allowed for cleaning of the diesel exhaust fluid injector.
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
*******Group 2*******
0-3000 hrs,
0-36 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 0.5-hour job for Group 2
For After failure, and additional 3 hours are allowed for cleaning of the diesel exhaust fluid injector.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.