101401-2331 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014012331

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-2331 1014012331

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Service parts 101401-2331 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9240

3. GOVERNOR 105401-0820

4. SUPPLY PUMP 105220-5590

5. AUTOM. ADVANCE MECHANIS 105676-1050

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5221

11. Nozzle and Holder 23600-2601A

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105041-5171

14. NOZZLE 105015-6240

15. NOZZLE SET

Include in #1:

101401-2331 as INJECTION-PUMP ASSEMBLY

101603-2390 as _

101603-2391

Cross reference number

ZEXEL 101401-2331 1014012331

Zexel num

Bosch num

Firm num

Name

101401-2331

INJECTION-PUMP ASSEMBLY

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 4.3 4.27 4.33

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point A

Rack position 11.5

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 115 113 117

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 45.3 45.3

Boost pressure mmHg 340 340

Injection quantity adjustment_02

Adjusting point C

Rack position 8.4+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10 8.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R1-1.7

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1(11.5)

Boost pressure kPa 32 32 32

Boost pressure mmHg 240 240 240

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min (1000)

Advance angle deg. 1.25 0.65 1.25

Load 4/4

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 1.25 0.65 1.25

Load 3/4

Timer adjustment_05

Pump speed r/min 1500

Advance angle deg. 4.5 4.2 4.8

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting (5)Boost compensator stroke: BCL
----------
K=9 BCL=1.7+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=11deg+-5deg b=26deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

Caterpillar: Confidential Yellow
PSP FOR ADDING HOLDDOWN BRACKET AND PLATE TO FUEL INJECTION LINES ON CERTAIN CHALLENGER 65 TRACTORS - MAILED US AND CANADA, LI MITED CACO, LIMITED COFA
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.
U-159 A-73.1 AU-98.1 1252 PS4250 This Program can be administered either before or after a failure. In either case the decision whether to apply the Program is made by the dealer. When reporting the repair, use "PS4250" as Part Number and "7755" as Group Number. Termination Date
October 31, 1989
Problem
The No. 1, No. 2, and No. 3 fuel injection lines may crack at the injector end of the lines due to vibration from injection pulses or engine combustion. A clamping plate and a hold-down bracket can be installed to the lines to reduce vibration.
Affected Product
Model Identification Number CH65 7YC1 - 824, 828-831, 835, 836, 841, 849, 851
Parts Needed
3 - 4B4274 Washer 3 - 1W9169 Clamp 3 - 9N3388 Screw 1 - 9Y7523 Bracket 3 - 1W9167 Clamp As. 1 - 9Y7524 Plate
Action Required
Install the parts needed as shown in Illustrations 1 and 2.
Service Claim Allowances
Product Caterpillar Dealer Suggested Customer Suggested smu/age Parts Labor Hrs. Parts Labor Hrs. Parts Labor Hrs. whichever (D/N) (Cost) (C/L) (Sell) comes first 0-2000 100% 1 0 0 0 0 0-24 mo 2001-4000 33 1/3% .5 0 .5 0 0 25-36 mo This is a 1-hour job.
Parts Disposition
Not applicable ****** IMAGE: SEBE3893.00001.001 CAPTION: Illustration 1. Top View Of Installation ****** IMAGE: SEBE3893.00001.002 CAPTION: Illustration 2. Side View Of Installation