Information injection-pump assembly
BOSCH
9 400 617 488
9400617488
ZEXEL
106681-4040
1066814040
MITSUBISHI-HEAV
35A6500060
35a6500060
Rating:
Service parts 106681-4040 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
35A61-00010
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106681-4040
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 617 488
9400617488
ZEXEL
106681-4040
1066814040
MITSUBISHI-HEAV
35A6500060
35a6500060
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
2.8
2.75
2.85
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor 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
14.1
Pump speed
r/min
980
980
980
Average injection quantity
mm3/st.
486
477
495
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
126.6
126.6
Boost pressure
mmHg
950
950
Injection quantity adjustment_02
Adjusting point
B
Rack position
6.7+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
25.5
22.5
28.5
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
R1-1.5
Boost pressure
kPa
73.3
70.6
76
Boost pressure
mmHg
550
530
570
Boost compensator adjustment_02
Pump speed
r/min
600
600
600
Rack position
R1(14.1)
Boost pressure
kPa
113.3
106.6
120
Boost pressure
mmHg
850
800
900
Timer adjustment
Pump speed
r/min
450--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
400
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
700
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Notch fixed: K
(2)Boost compensator stroke
----------
K=14
----------
----------
K=14
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(23deg)+-5deg b=(41deg)+-5deg
----------
----------
a=(23deg)+-5deg b=(41deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa, rack position bb
----------
aa=0r/min bb=1-0.5mm
----------
a=33deg+-5deg b=(73deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=33deg+-5deg b=(73deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(110deg)
----------
----------
a=(110deg)
Information:
August 31, 2004
O-219
Priority PRODUCT IMPROVEMENT PROGRAM FOR REPLACINGTHE INJECTION ACTUATION PRESSURE SENSOR ON CERTAIN 3126E ENGINES
7755,1925 PI30676
This Program must be administered assoon as possible. When reporting the repair, use "PI30676" as the Partnumber and "7751" as the Group Number, "56" as the Warranty Claim DescriptionCode and "T" as the SIMS Description Code. Exception: If the repair isdone after failure, use "PI30676" as the Part Number, "7751" as the GroupNumber, "96" as the Warranty Claim Description Code, and "Z" as the SIMSDescription 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.
COMPLETION DATE
TERMINATION DATE
February 28, 2005 August 31, 2005PROBLEM
Replace the injection actuation pressure sensorcertain 3126E engines. The old sensor may leak oil.AFFECTED PRODUCT
Model IdentificationNumber
3126E G3E230-497PARTS NEEDED
Qty
Part Number Description
1 2244536 SENSOR GP-PRACTION REQUIRED
Remove the 194-6726 Pressure Sensor and replaceit with part number 224-4536 Pressure Sensor.OWNER NOTIFICATION
U.S. and Canadian owners will receive the attachedOwner Notification.SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts LaborHrs Parts LaborHrs
100% 1.0 0 0 0 0
This is a 1.0-hour job. U.S. and Canadian Dealers Only - Eligibledealers may enter a Type 2 SIMS ReportPARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.MAKE EVERY EFFORT TO COMPLETE THIS PROGRAMAS SOON AS POSSIBLE.Attach. (Owner Notification)COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999PRIORITY - THE INJECTION ACTUATION PRESSURESENSOR NEEDS TO BE REPLACED.MODELS INVOLVED - CERTAIN 3126E ENGINESDear Caterpillar Product Owner:A new injection actuation pressure sensor needsto be installed on the products listed below. The current sensor may leakoil. You will not be charged for the service performed.Contact your local Caterpillar dealer immediatelyto schedule this service. The dealer will advise you of the time requiredto complete this service. Please refer the dealer to their Service Letterdated August 31, 2004 when scheduling this service.We regret the inconvenience this may causeyou, but urge you to have this service performed as soon as possible toprevent unscheduled downtime.Caterpillar Inc.
Identification #(s)Attached to August 31, 2004 Service Letter
O-219
Priority PRODUCT IMPROVEMENT PROGRAM FOR REPLACINGTHE INJECTION ACTUATION PRESSURE SENSOR ON CERTAIN 3126E ENGINES
7755,1925 PI30676
This Program must be administered assoon as possible. When reporting the repair, use "PI30676" as the Partnumber and "7751" as the Group Number, "56" as the Warranty Claim DescriptionCode and "T" as the SIMS Description Code. Exception: If the repair isdone after failure, use "PI30676" as the Part Number, "7751" as the GroupNumber, "96" as the Warranty Claim Description Code, and "Z" as the SIMSDescription 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.
COMPLETION DATE
TERMINATION DATE
February 28, 2005 August 31, 2005PROBLEM
Replace the injection actuation pressure sensorcertain 3126E engines. The old sensor may leak oil.AFFECTED PRODUCT
Model IdentificationNumber
3126E G3E230-497PARTS NEEDED
Qty
Part Number Description
1 2244536 SENSOR GP-PRACTION REQUIRED
Remove the 194-6726 Pressure Sensor and replaceit with part number 224-4536 Pressure Sensor.OWNER NOTIFICATION
U.S. and Canadian owners will receive the attachedOwner Notification.SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts Labor Hrs Parts LaborHrs Parts LaborHrs
100% 1.0 0 0 0 0
This is a 1.0-hour job. U.S. and Canadian Dealers Only - Eligibledealers may enter a Type 2 SIMS ReportPARTS DISPOSITION
Handle the parts in accordance with your WarrantyBulletin on warranty parts handling.MAKE EVERY EFFORT TO COMPLETE THIS PROGRAMAS SOON AS POSSIBLE.Attach. (Owner Notification)COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999PRIORITY - THE INJECTION ACTUATION PRESSURESENSOR NEEDS TO BE REPLACED.MODELS INVOLVED - CERTAIN 3126E ENGINESDear Caterpillar Product Owner:A new injection actuation pressure sensor needsto be installed on the products listed below. The current sensor may leakoil. You will not be charged for the service performed.Contact your local Caterpillar dealer immediatelyto schedule this service. The dealer will advise you of the time requiredto complete this service. Please refer the dealer to their Service Letterdated August 31, 2004 when scheduling this service.We regret the inconvenience this may causeyou, but urge you to have this service performed as soon as possible toprevent unscheduled downtime.Caterpillar Inc.
Identification #(s)Attached to August 31, 2004 Service Letter