101402-3871 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014023871

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-3871 1014023871

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101402-3871 zexel genuine, new aftermarket engine parts with delivery

Service parts 101402-3871 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9260

3. GOVERNOR 105404-5221

4. SUPPLY PUMP

105220-5960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

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

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

101402-3871 as INJECTION-PUMP ASSEMBLY

108822-3298 as _

Cross reference number

ZEXEL 101402-3871 1014023871

Zexel num

Bosch num

Firm num

Name

101402-3871

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 131424-3420

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 2.5 2.45 2.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 10.5

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 83 82 84

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 51.3 51.3

Boost pressure mmHg 385 385

Hydraulic cylinder ON *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.5+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 9 8 10

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder ON *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 85 95

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Hydraulic cylinder OFF *

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-1

Boost pressure kPa 24.7 23.4 26

Boost pressure mmHg 185 175 195

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(10.5)

Boost pressure kPa 38 31.3 44.7

Boost pressure mmHg 285 235 335

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)The torque control spring does not operate. (4)Adjust the secondary timing before adjusting the governor. (5)RACK LIMIT (When hydraulic cylinder is OFF) (6)Boost compensator stroke: BCL (7)When the hydraulic cylinder is ON (P1)
----------
K=6 BCL=1+-0.1mm P1=((392)kPa{(4)kgf/cm2})
----------

Speed control lever angle

F:Full speed I:Idle (1)- (2)Stopper bolt setting
----------

----------
a=11deg+-5deg b=22deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Without return spring
----------

----------
a=0deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Key groove position at No. 1 cylinder's beginning of injection position (at BTDC: aa). (3)Position of the key groove of the No. 1 cylinder at B.T.D.C. bb (fix the governor flyweight at this position for delivery). (4)B.T.D.C.: aa (5)At second timing adjustment, set the camshaft at the * position and tighten the flyweight locknut. (6)Align the flyweight's timing gear position with the lockpin groove and then fully tighten the flyweight to the camshaft. (7)Remove the lock pin and adjust the governor. Reinstall the lock pin to fix the flyweight for delivery.
----------
aa=16deg bb=0deg
----------
a=54deg54min+-3deg b=8deg+-30min

Information:

This Program must be administered assoon as possible. When reporting the repair, use "PI30156" 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 "PI30156" 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. This Revised Service Letter replacesthe March 24, 2001 Service Letter. Changes were made to Parts Needed, ReworkProcedure, Service Claim Allowances, Owner Notification and Parts Disposition. This Service Letter should not be performedon engines with greater than 7500 miles (>12000 KM) or >150 hours.
COMPLETION DATE
TERMINATION DATE
September 30, 2001 March 31, 2002PROBLEM
Due to a manufacturing error, there is a possibilitythat numerous 1043568 Injector Pushrods missed the heat treating operation.Certain C-10, C-12, 3176C, and 3196 engines will need to have the injectorpushrods checked and possibly replaced. This Service letter should onlybe performed on engines with between 0 to 7500 miles (0 to 12000 kM) or0-150 hours.AFFECTED PRODUCT
Model Identification NumberTRUCK/COMMERCIAL ENGINESC-10 3CS18811 ? 193268YS7628 - 7646C-12 2KS61890 ? 632739SM277 - 3363176C IND 2AW1272 ? 13063196 IND 1DW611 ? 6143176C MAR 6BW498 ? 4993196 MAR 2XR3757 ? 38623176C Machine 3PD168 - 2023196 Machine 5ED216 - 2373176C Machine 7ZR5409 - 55163196 Machine 6AR2595 - 2635MACHINES725 AFX130-131, 142-145, 148-150,174, 177-179730 AGF217-218, 225-228345 AGS480, 562, 564, 566, 571,575, 578, 582-584ALB197APB110-112CFM27665E 6GS632, 634, 637, 639?649, 65275E 1HM310-3126HS647, 64985E 1NM230-2316JS668-669, 67295E 1SM282 ? 2896KS985, 987, 993PARTS NEEDED
AS REQUIRED
1043568 Injector Pushrods(depending on the results of the inspection,0?6 pushrods may be needed for the rework? Only individual pushrods foundto be soft need to be replaced)AS REQUIRED
Injector Group(depending on the results of the pushrodinspection , 0-6 injectors may be needed for the rework? An injector shouldbe replaced only if the pushrod for that particular injector isfound to be soft and if the engine has more than 200 MILES (322KM) or 20 HOURS.)ACTION REQUIRED
Remove the valve covers.
Using a medium to coarse flat file against thecup of the pushrod, stroke the file.
If the push rod is soft you will feel a distinctdrag as the file digs into the material.
If the push rod is hard the file will feel likeit is passing over glass as the file slides across the hard surface.
If you are not certain if a pushrod is soft orhard CALL YOUR TC OR THE CAT PRODUCT ANALYST AT:(800)447-4986.
If a pushrod is soft, remove the rocker arm andreplace the pushrod. Tighten the rocker stand bolts according to the torquevalue found in Service Manual.
IF A PUSHROD IS FOUND TO BE SOFT AND THE ENGINEHAS MORE THAN 200 miles (322 KM) OR 20 hours on it replace onlythe injector that is driven by the soft pushrod. Lubricate the two largero-ring seals with engine oil and install the injectors. Tighten the injectorhold down