Information injection-pump assembly
ZEXEL
101608-6100
1016086100
Rating:
Cross reference number
ZEXEL
101608-6100
1016086100
Zexel num
Bosch num
Firm num
Name
101608-6100
INJECTION-PUMP ASSEMBLY
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)
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
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
9.8
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
71.5
70.5
72.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.4+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
65
70
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
0
Advance angle
deg.
2
1.5
2.5
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
2
1.5
2.5
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_03
Pump speed
r/min
850+-25
Advance angle
deg.
0
0
0
Remarks
Finish
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)Supplied with torque spring not set.
(4)RACK LIMIT
(5)Set idle sub-spring
(6)Main spring setting
----------
K=9
----------
----------
K=9
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=5deg+-5deg b=24deg+-5deg
----------
----------
a=5deg+-5deg b=24deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
a=27deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=12.5deg
----------
a=(130deg)
----------
aa=12.5deg
----------
a=(130deg)
Information:
REM07-17
Reman
August 2007 APPEARANCE CHANGE TO REMAN ELECTRONIC & HEUI? INJECTORS
Announcement
The Caterpillar Remanufactured Products Group announces an appearance change on selected Cat? Reman Electronic & HEUI? Injectors.
In order to improve the salvage of EUI and HEUI injector components Cat Reman is introducing a new Metal Deposition process around the sealing cone/case on electronic injectors and HEUI injectors for the families mentioned above. Validation Tests confirm change will not alter quality, reliability, fit or performance in any way. Appearance with this new Metal Deposition process before and after use for acceptable cases are as shown below (Reference: EI800 (B) Injector assembly).
Effective July 2007, this appearance change affects part numbers in the following families: EI400, EI800, MI550, EI550 Classic and Bridge, EI500 and EI550 with ACERTTM Technology electronic injectors and HEUI series HI300 CAT, HIA250 and HIA450 Injectors. Refer to the table below for a complete part number listing by family.
Features And Benefits
Cat Remanufactured injectors 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 injectors. Cat Remanufactured injectors provide immediate, off-the-shelf availability at a fraction of the new price.
Core Acceptance
Core Acceptance Criteria for Caterpillar Remanufactured injectors 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.
PELJ0797 CATERPILLAR? ?2007 Caterpillar
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Group cross 101608-6100 ZEXEL
101608-6100
INJECTION-PUMP ASSEMBLY