101608-6090 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016086090

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-6090 1016086090

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Service parts 101608-6090 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101062-8180

3. GOVERNOR 105932-3070

4. SUPPLY PUMP 105210-6020

5. AUTOM. ADVANCE MECHANIS 105643-1170

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7522

11. Nozzle and Holder ME072745

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE

15. NOZZLE SET 105019-0690

Include in #1:

101608-6090 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-0232 as _

Cross reference number

ZEXEL 101608-6090 1016086090

Zexel num

Bosch num

Firm num

Name

101608-6090

INJECTION-PUMP ASSEMBLY
14BF PE6AD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 18

Opening pressure kgf/cm2 184

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-8420

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 12.5

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 113 109.6 116.4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 280 280 280

Each cylinder's injection qty mm3/st. 11.5 9.8 13.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.5)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 113 112 114

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 117.5 113.5 121.5

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 65)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 108.5 104.5 112.5

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2-0.45

Boost pressure kPa 13.3 13.3 13.3

Boost pressure mmHg 100 100 100

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2-0.3

Boost pressure kPa 16.7 15.4 18

Boost pressure mmHg 125 115 135

Boost compensator adjustment_03

Pump speed r/min 500 500 500

Rack position R2(R1-0. 65)

Boost pressure kPa 22.7 22.7 22.7

Boost pressure mmHg 170 170 170

Timer adjustment

Pump speed r/min 1200--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1350

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=M90 BCL=0.45+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=18.5deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=1350r/min bb=7-0.5mm cc=275r/min dd=(8.6)mm
----------
a=11.5deg+-5deg b=28deg+-5deg

0000001501 LEVER

(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=40deg+-3deg c=18.5deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(2deg)

Information:

REM07-12
Reman
July 2007 APPEARANCE CHANGE TO CAT REMAN DIFN NOZZLES
Announcement
The Caterpillar Remanufactured Products Group announces a change on selected Cat? Reman DIFN nozzles. Currently, the nozzles include an edge filter located in the adapter. Effective on 07/02/07, Reman will not include edge filters in nozzles as an improvement to the source of debris caused by the edge filter movement and or chipping the corners when pressing the filter inside the adapter. This change will not alter fit or performance in any way.
Part Numbers Impacted
The table below lists part numbers impacted by this change.
Features And Benefits
Cat Remanufactured fuel nozzles offer excellent value to customers. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of these Remanufactured fuel nozzles. Cat Remanufactured fuel nozzles provide immediate, off-the-shelf availability at a fraction of the new price.
Core Acceptance
Core Acceptance Criteria for Caterpillar Remanufactured Engine Components is simple, visual, and requires no special tools. Consult your Core Acceptance Guide for complete details.
Warranty
Please consult the appropriate warranty statement for your area.
Core Management
Please refer to the Caterpillar Core Management Information System (CMIS 2) Parts Information application describing all reman part/CAF and related information. Also refer to other CMIS 2 inquiry applications such as Customer Profiles, Inspection Reason Codes, Inspection Line Inquiry, Add Charge Information, Entitlement Activity, Entitlement Inquiry, CCR Inquiry, CCR Entry, Shipment Processing; Process Packaging Grief; and Reporting to properly manage core returns and monitor inspection performance. This information will be available to all dealers worldwide after your CMIS 2 conversion date. In the meantime, please continue to use the current CMIS Entitlement Parts Inquiry Screen describing the list of parts in a Core Acceptability Family (CAF) and related part number detail.
For the latest updates of Reman Policies and Core Management (SELD0122), Core Management Systems & Operations Procedures (SELD0040), and Shipping Instructions (SELD0039), go to the Reman Dealer website https://reman.cat.com
If you have any questions regarding core return processing, feel free to call Corinth toll free at (800) 537-2928. For assistance with technical questions, call the Peoria Reman
Technical Help Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.
PELJ0782 CATERPILLAR? ?2007 Caterpillar