Information injection-pump assembly
BOSCH
F 019 Z10 596
f019z10596
ZEXEL
101602-9950
1016029950
MITSUBISHI-HEAV
3436101030
3436101030
Rating:
Service parts 101602-9950 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 596
f019z10596
ZEXEL
101602-9950
1016029950
MITSUBISHI-HEAV
3436101030
3436101030
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
8.5
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
74.2
73.2
75.2
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.6+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
12
10.7
13.3
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
D
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)Deliver without the torque control spring operating.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
----------
K=15
----------
----------
K=15
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=14deg+-5deg b=29deg+-5deg
----------
----------
a=14deg+-5deg b=29deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
----------
----------
a=26.5deg+-5deg b=53deg+-5deg
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:
March 21, 2006
U-89
A-70
D-67
O-77
Beforeor
after failureParts stock action needed PRODUCT SUPPORT PROGRAM FOR REPLACINGTHE FUEL INJECTION PUMP VOLTAGE LOAD PROTECTION CONTROL ON CERTAIN 924G,928G, AND 930G WHEEL LOADERS
12881251 PS41980
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 "PS41980"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. Although this Program is to be administeredas described above on the Affected Product, parts should be removed fromparts stock as soon as possible. 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.TERMINATION DATE
March 31, 2007PROBLEM
Voltage Load Protection Module may fail due tomoisture entry resulting in unexpected engine shut down.AFFECTED PRODUCT
Model IdentificationNumber
924G DDA375-378,380-780, 782-1538, 1540-1953, 1955-2090, 2093-2105, 2107, 2108, 2111-2113,2115, 2117, 2119-2121, 2125, 2133-2134, 2136, 2201, 2272, 2622, 2627, 2642DFZ350-381, 383-563RBB175-977, 979-982, 984-985RTA150-476, 478, 480WGX285-842WMB295-895
928G DJD323-711,713-972, 974-1179, 1181-1418, 1420-1479, 1481-1577, 1579-1662, 1664-1811,1813-1934, 1936-1939, 1941-1943, 1949, 2315, 2322WLG265-809
IT28G DBT345-1489,1491-1676EWF100-421WAC275-622
930G TFW150-193TWR233-286, 288-637, 639-642, 644,646-669, 671-675, 677-678, 680-681, 683, 685-686, 689-691, 693-697, 699,701-703, 708-711, 713-716, 718, 721-723, 725-726, 729, 731-735, 737-738,740-741, 745, 747, 750-751, 754, 758, 761-764, 767, 769, 772, 774, 777,779-782, 789-791, 793, 800-801, 805-806, 809, 811, 830-831, 864, 874, 878,905, 921, 927-928, 1295, 1634PARTS NEEDED
Qty
Part Number Description
1 2705322 CONTROL GPACTION REQUIRED
***** Parts Stock *****Remove all 2159430 Control Groups from partsstock.***** Affected Product *****Replace 2159430 with 2705322 and confirm theengine operates.SERVICE CLAIM ALLOWANCES
***** Parts Stock *****Submit one claim for all 2159430 Control Groupsremoved from parts stock.***** Affected Product *****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-3000
0-24 mos 100% 1.0 0 0 0 0
3001 - 5000
25 ? 36 mos 33.3% 0.5 0 0 50% 0.5
This is a 1.0 hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.
U-89
A-70
D-67
O-77
Beforeor
after failureParts stock action needed PRODUCT SUPPORT PROGRAM FOR REPLACINGTHE FUEL INJECTION PUMP VOLTAGE LOAD PROTECTION CONTROL ON CERTAIN 924G,928G, AND 930G WHEEL LOADERS
12881251 PS41980
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 "PS41980"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. Although this Program is to be administeredas described above on the Affected Product, parts should be removed fromparts stock as soon as possible. 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.TERMINATION DATE
March 31, 2007PROBLEM
Voltage Load Protection Module may fail due tomoisture entry resulting in unexpected engine shut down.AFFECTED PRODUCT
Model IdentificationNumber
924G DDA375-378,380-780, 782-1538, 1540-1953, 1955-2090, 2093-2105, 2107, 2108, 2111-2113,2115, 2117, 2119-2121, 2125, 2133-2134, 2136, 2201, 2272, 2622, 2627, 2642DFZ350-381, 383-563RBB175-977, 979-982, 984-985RTA150-476, 478, 480WGX285-842WMB295-895
928G DJD323-711,713-972, 974-1179, 1181-1418, 1420-1479, 1481-1577, 1579-1662, 1664-1811,1813-1934, 1936-1939, 1941-1943, 1949, 2315, 2322WLG265-809
IT28G DBT345-1489,1491-1676EWF100-421WAC275-622
930G TFW150-193TWR233-286, 288-637, 639-642, 644,646-669, 671-675, 677-678, 680-681, 683, 685-686, 689-691, 693-697, 699,701-703, 708-711, 713-716, 718, 721-723, 725-726, 729, 731-735, 737-738,740-741, 745, 747, 750-751, 754, 758, 761-764, 767, 769, 772, 774, 777,779-782, 789-791, 793, 800-801, 805-806, 809, 811, 830-831, 864, 874, 878,905, 921, 927-928, 1295, 1634PARTS NEEDED
Qty
Part Number Description
1 2705322 CONTROL GPACTION REQUIRED
***** Parts Stock *****Remove all 2159430 Control Groups from partsstock.***** Affected Product *****Replace 2159430 with 2705322 and confirm theengine operates.SERVICE CLAIM ALLOWANCES
***** Parts Stock *****Submit one claim for all 2159430 Control Groupsremoved from parts stock.***** Affected Product *****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts Labor Hrs Parts Labor Hrs
0-3000
0-24 mos 100% 1.0 0 0 0 0
3001 - 5000
25 ? 36 mos 33.3% 0.5 0 0 50% 0.5
This is a 1.0 hr job.PARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.