Information injection-pump assembly
ZEXEL
101609-9250
1016099250
MITSUBISHI-HEAV
3436507021
3436507021
Rating:
Cross reference number
ZEXEL
101609-9250
1016099250
MITSUBISHI-HEAV
3436507021
3436507021
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
3.5
3.45
3.55
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
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
9
Pump speed
r/min
895
895
895
Average injection quantity
mm3/st.
102.5
101.5
103.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.8+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
13
11.7
14.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
9.2++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
105
105
110
Fixing the lever
*
Rack limit
*
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)RACK LIMIT
(4)Rack difference between N = N1 and N = N2
(5)Set idle sub-spring
----------
K=5 N1=895r/min N2=400r/min
----------
----------
K=5 N1=895r/min N2=400r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=31deg+-3deg b=12.5deg+-5deg c=5.5deg+-5deg
----------
----------
a=31deg+-3deg b=12.5deg+-5deg c=5.5deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Speed = bb, rack position = cc (sealed at delivery)
(3)Normal
----------
aa=25mm bb=0r/min cc=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=25mm bb=0r/min cc=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
0000001501 I/P WITH LOAD PLUNGER ADJ
Load plunger-equipped pump adjustment
1. Adjust the variation between cylinders and the injection quantity.
2. At Full point A, adjust the pre-stroke to the specified value.
3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
----------
----------
----------
----------
Timing setting
(1)Pump vertical direction
(2)Position of camshaft's key groove at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=4deg
----------
a=(50deg)
----------
aa=4deg
----------
a=(50deg)
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
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