Information injection-pump assembly
ZEXEL
101602-9932
1016029932
MITSUBISHI-HEAV
3436100092
3436100092
Rating:
Service parts 101602-9932 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
34361-11010
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
ZEXEL
101602-9932
1016029932
MITSUBISHI-HEAV
3436100092
3436100092
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
131424-5720
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
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
1-5-3-6-
2-4
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 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
7.7
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
48
47
49
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
58
58
63
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)The torque control spring must does not have a set force.
(4)Set idle sub-spring
(5)Main spring setting
----------
K=6
----------
----------
K=6
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=7deg+-5deg b=30deg+-5deg
----------
----------
a=7deg+-5deg b=30deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Hold the boss against the stop side
----------
----------
a=26.5deg+-5deg b=53deg+-5deg c=(9deg)
----------
----------
a=26.5deg+-5deg b=53deg+-5deg c=(9deg)
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
September 13, 2003
(Revised October 2003)
U-250
A-177
D-181
O-210
beforeor
after failure PRODUCT SUPPORT PROGRAM FOR REPLACINGTHE INJECTION ACTUATION PRESSURE SENSOR ON CERTAIN 938G-II, 950G-II, 962G-IIWHEEL LOADERS AND IT62G-II, IT38G-II INTEGRATED TOOLCARRIERS
1925 PS41385
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS41385"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe September 13, 2003 Service Letter. Changes have been made to the Titleand Affected Product.TERMINATION DATE
September 30, 2005PROBLEM
The injection actuation pressure sensor needsto be replaced on certain 938G-II, 950G-II, 962G-II Wheel Loaders and IT38G-IIIntegrated Toolcarriers. The 1946726 sensor may leak so it needs to bereplaced with the 2244536 sensor.AFFECTED PRODUCT
Model IdentificationNumber
938G II CRD1-435PHN1-549
950G II AXR1-243AXX1-386AYL1-1038AYB1-692AYD227-228AYS111-160BAA111-320
962G II AXY1-258AXS364-375AYE1-529AYG364-370BAB1-436BAC213-235BAD213-265
IT62G II AYA109-145
IT38G II CSX1-349PARTS NEEDED
Qty
Part Number Description
1 2244536 SENSOR GP-PRACTION REQUIRED
Remove 1946726 injection actuation pressure sensor.
Replace with 2244536 injection actuation pressuresensor.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-4000 hrs
0-24 mos 100% 1.0 0 0 0 0
This is a 1.0?hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
(Revised October 2003)
U-250
A-177
D-181
O-210
beforeor
after failure PRODUCT SUPPORT PROGRAM FOR REPLACINGTHE INJECTION ACTUATION PRESSURE SENSOR ON CERTAIN 938G-II, 950G-II, 962G-IIWHEEL LOADERS AND IT62G-II, IT38G-II INTEGRATED TOOLCARRIERS
1925 PS41385
This Program can be administered eitherbefore or after failure. In either case the decision whether to apply theProgram is made by the dealer. When reporting the repair, use "PS41385"as the Part number and "7755" as the Group Number. If administered beforefailure, use "56" as the Warranty Claim Description Code and use "T" asthe SIMS Description Code. If administered after failure, use "96" as theWarranty Claim Description Code and use "Z" as the SIMS Description Code. The information supplied in this serviceletter may not be valid after the termination date of this program. Donot perform the work outlined in this Service Letter after the terminationdate without first contacting your Caterpillar product analyst. This Revised Service Letter replacesthe September 13, 2003 Service Letter. Changes have been made to the Titleand Affected Product.TERMINATION DATE
September 30, 2005PROBLEM
The injection actuation pressure sensor needsto be replaced on certain 938G-II, 950G-II, 962G-II Wheel Loaders and IT38G-IIIntegrated Toolcarriers. The 1946726 sensor may leak so it needs to bereplaced with the 2244536 sensor.AFFECTED PRODUCT
Model IdentificationNumber
938G II CRD1-435PHN1-549
950G II AXR1-243AXX1-386AYL1-1038AYB1-692AYD227-228AYS111-160BAA111-320
962G II AXY1-258AXS364-375AYE1-529AYG364-370BAB1-436BAC213-235BAD213-265
IT62G II AYA109-145
IT38G II CSX1-349PARTS NEEDED
Qty
Part Number Description
1 2244536 SENSOR GP-PRACTION REQUIRED
Remove 1946726 injection actuation pressure sensor.
Replace with 2244536 injection actuation pressuresensor.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-4000 hrs
0-24 mos 100% 1.0 0 0 0 0
This is a 1.0?hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.