Information injection-pump assembly
ZEXEL
101606-1180
1016061180
Rating:
Cross reference number
ZEXEL
101606-1180
1016061180
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
131424-5520
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)
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
3.3
3.25
3.35
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
9
Pump speed
r/min
875
875
875
Average injection quantity
mm3/st.
60.3
59.3
61.3
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
7.7+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
9.2
7.7
10.7
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Timer adjustment
Pump speed
r/min
850--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
800
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
0.8
0.3
1.3
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
5
5
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Rack difference between N = N1 and N = N2
(3)Rack difference between N = N3 and N = N4
----------
K=5 N1=875r/min N2=670r/min N3=875r/min N4=500r/min
----------
----------
K=5 N1=875r/min N2=670r/min N3=875r/min N4=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=4deg+-5deg b=14deg+-5deg
----------
----------
a=4deg+-5deg b=14deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=26deg+-5deg b=53deg+-5deg
----------
----------
a=26deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '2' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18deg
----------
a=(90deg)
----------
aa=18deg
----------
a=(90deg)
Information:
Contact your Caterpillar dealer for part numbers and available container sizes.
This oil is formulated for transmissions and drive trains only, and should not be used in engines. Shortened engine service life will result.Do not use Caterpillar Gear Oil (GO) in marine transmissions. Gear Oil can cause seal material to fail and possibly leak. Gear Oil also may not be compatible with friction materials and can reduce transmission efficiency.
Multi-grade oils are not currently blended by Caterpillar for use in transmissions. Multi-grade oils which use high molecular weight polymers as viscosity index improvers lose their viscosity effectiveness by permanent and temporary shear of the viscosity index improver. Therefore, multi-grade oils are not recommended for transmissions. The Caterpillar TO-4 specification does include a test for multi-grade oil shear stability. Multi-grade oils with adequate shear stability may be available in the future.Commercial Transmission/Drive Train Oils
If Caterpillar Transmission/Drive Train Oil is not used, commercial oils meeting the Caterpillar TO-4 specification must be used in Caterpillar marine transmissions:* TO-4 Specification Oils, single grade onlyCommercial Marine Transmissions
For marine transmissions which are not manufactured by Caterpillar, refer to the marine transmission or vessel OEM lubrication recommendations.S O S Oil Analysis
Caterpillar's Scheduled Oil Sampling (S O S) Oil Analysis should be a part of an engine's overall maintenance program. The S O S program monitors the engine and transmission through used oil analysis. The oil analysis measures wear metals and oil condition. Deviations from established limits or trend lines can diagnose an impending problem before the problem becomes apparent, costly, and destructive.See your Caterpillar dealer for more information regarding S O S Oil Analysis and how the program can help you manage your engine and transmission.Engine Lubricant Recommendations Summary
To achieve all the performance that was built into a Caterpillar engine, follow these guidelines:* Select the proper Caterpillar oil or commercial oil that meets the API specifications* Select the proper oil viscosity based on the applicable Lubricant Viscosities chart* Replace the engine oil and oil filter(s) at the intervals specified in the Operation and Maintenance Manual* Perform maintenance according to the Operation and Maintenance ManualCaterpillar Lubricating Grease
Caterpillar provides grease for a variety of applications and extreme temperature conditions. The descriptions of these products follow.Contact your Caterpillar dealer for part numbers and available container sizes. One grease may be incompatible with another grease. When using commercial grease, make sure the grease is compatible with the grease used in your system, or make sure to purge the system. Contact your supplier regarding grease compatibility questions.Multipurpose Grease
Multipurpose Lithium Complex Grease (MPG)
MPG is a NLGI No.2 general purpose lithium complex grease for light to medium duty applications. MPG has good high temperature characteristics, with a minimum dropping point of 260°C (500°F). MPG contains unleaded extreme pressure additives and anti-wear and corrosion inhibitors to provide extra protection in a variety of construction, agricultural and automotive applications.MPG meets the requirements for extended service intervals of automotive chassis points and wheel bearings with disc brakes, particularly in passenger cars, vans, light trucks and taxi fleets.
This oil is formulated for transmissions and drive trains only, and should not be used in engines. Shortened engine service life will result.Do not use Caterpillar Gear Oil (GO) in marine transmissions. Gear Oil can cause seal material to fail and possibly leak. Gear Oil also may not be compatible with friction materials and can reduce transmission efficiency.
Multi-grade oils are not currently blended by Caterpillar for use in transmissions. Multi-grade oils which use high molecular weight polymers as viscosity index improvers lose their viscosity effectiveness by permanent and temporary shear of the viscosity index improver. Therefore, multi-grade oils are not recommended for transmissions. The Caterpillar TO-4 specification does include a test for multi-grade oil shear stability. Multi-grade oils with adequate shear stability may be available in the future.Commercial Transmission/Drive Train Oils
If Caterpillar Transmission/Drive Train Oil is not used, commercial oils meeting the Caterpillar TO-4 specification must be used in Caterpillar marine transmissions:* TO-4 Specification Oils, single grade onlyCommercial Marine Transmissions
For marine transmissions which are not manufactured by Caterpillar, refer to the marine transmission or vessel OEM lubrication recommendations.S O S Oil Analysis
Caterpillar's Scheduled Oil Sampling (S O S) Oil Analysis should be a part of an engine's overall maintenance program. The S O S program monitors the engine and transmission through used oil analysis. The oil analysis measures wear metals and oil condition. Deviations from established limits or trend lines can diagnose an impending problem before the problem becomes apparent, costly, and destructive.See your Caterpillar dealer for more information regarding S O S Oil Analysis and how the program can help you manage your engine and transmission.Engine Lubricant Recommendations Summary
To achieve all the performance that was built into a Caterpillar engine, follow these guidelines:* Select the proper Caterpillar oil or commercial oil that meets the API specifications* Select the proper oil viscosity based on the applicable Lubricant Viscosities chart* Replace the engine oil and oil filter(s) at the intervals specified in the Operation and Maintenance Manual* Perform maintenance according to the Operation and Maintenance ManualCaterpillar Lubricating Grease
Caterpillar provides grease for a variety of applications and extreme temperature conditions. The descriptions of these products follow.Contact your Caterpillar dealer for part numbers and available container sizes. One grease may be incompatible with another grease. When using commercial grease, make sure the grease is compatible with the grease used in your system, or make sure to purge the system. Contact your supplier regarding grease compatibility questions.Multipurpose Grease
Multipurpose Lithium Complex Grease (MPG)
MPG is a NLGI No.2 general purpose lithium complex grease for light to medium duty applications. MPG has good high temperature characteristics, with a minimum dropping point of 260°C (500°F). MPG contains unleaded extreme pressure additives and anti-wear and corrosion inhibitors to provide extra protection in a variety of construction, agricultural and automotive applications.MPG meets the requirements for extended service intervals of automotive chassis points and wheel bearings with disc brakes, particularly in passenger cars, vans, light trucks and taxi fleets.