101608-6140 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016086140

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-6140 1016086140

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Cross reference number

ZEXEL 101608-6140 1016086140

Zexel num

Bosch num

Firm num

Name

101608-6140

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 131424-5520

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 4.5 4.45 4.55

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 A

Rack position 10.6

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 108 107 109

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 50.7 50.7

Boost pressure mmHg 380 380

Injection quantity adjustment_02

Adjusting point C

Rack position 7.6+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 9.5 8 11

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 110 130

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-0.7

Boost pressure kPa 22.7 20 25.4

Boost pressure mmHg 170 150 190

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(10.6)

Boost pressure kPa 37.3 30.6 44

Boost pressure mmHg 280 230 330

Timer adjustment

Pump speed r/min 1100++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1100.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 4 4 4

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting (6)Boost compensator stroke: BCL
----------
K=10 BCL=0.7+-0.1mm
----------

Speed control lever angle

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

----------
a=(20deg)+-5deg b=(5deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=35deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(7deg)

Information:

Features
Benefits
All critical engineering changes and updates included
Improved reliability and performance
Worldwide availability through Cat parts distribution system
Customer access regardless of location
Off-the-shelf availability
Downtime reduced through exchange product
Same-as-new Caterpillar warranty
Consistent support
Coverage Chart
Reman PN
New PN
Part Name
20R1298
3594090
INJECTOR GP - FUEL
20R1299
3494080
INJECTOR GP - FUEL
20R1301
3594020
INJECTOR GP - FUEL
20R1302
3594040
INJECTOR GP - FUEL
20R1303
3594070
INJECTOR GP - FUEL
20R1304
3597434
INJECTOR GP - FUEL
20R1308
3594050
INJECTOR GP - FUEL
20R1302
3594040
INJECTOR GP - FUEL
20R1317
3809889
INJECTOR GP - FUEL
20R1318
3674293
INJECTOR GP - FUEL
20R3247
3920225
INJECTOR GP - FUEL
20R3607
3820709
INJECTOR GP - FUEL
20R3608
3820745
INJECTOR GP – FUEL
20R3815
3689171
PUMP GP – FUEL INJ
20R3816
3689172
PUMP GP – FUEL INJ
20R3817
3689173
PUMP GP – FUEL INJ
Core Acceptance
The following Core Acceptance Criteria are available supporting these products. All the latest Core Acceptance Criteria guidelines can be found on the Reman Dealer Extranet at https://catreman.cat.com/cac
SELD0226 Unit Injectors Electronic
SELD0023 Fuel Pump & Governor Groups
Warranty
Please consult the appropriate warranty statement for your area by going to warranty.cat.com.
Core Management
Please refer to the Caterpillar Core Management Information System (CMIS 2) related to the parts information application that describes all Reman part/Core Acceptability Family (CAF) and other related information. Also, refer to other CMIS 2 inquiry applications such as: Dealer Customer Profile, Inspection Reason Codes, Inspection Line Inquiry, Dealer Add Charges, Dealer Entitlement Activity, Dealer CCR Inquiry, Dealer CCR Entry, Dealer Shipment Processing, Dealer Process Packaging Grief and Reporting. This information is available to all dealers worldwide that have been converted to CMIS 2.
Please go to the Reman web site https://catreman.cat.com for the latest policy and procedural updates that are available to all dealers worldwide explaining policy and procedural information such as “Policy and Core Management” -SELD0122; “Core Management Systems and Operations Procedures” -SELD0040; “Reman Core Return Packaging Instructions And Guidelines” -SELD0300; and “Shipping Instructions” SELD0039.
If you have any questions regarding Reman Core Management or Core Management Systems (CMIS2), feel free to call your Corinth Dealer Service Representative toll free at (800) 537-2928.
Contact Information:
For assistance with technical questions, call the Reman Technical Hot Line also toll free at (888) 88-REMAN or use our e-mail address--Reman_Help.
Global Dealer Solutions Network Parts Technical Support Team Toll Free -North America: 1-877-228-2420 International: +1-309-266-4421 Electronic Requests: Send via Microsoft Customer Relationship Management (MSCRM). For access and tutorial information: https://gdsn.cat.com/mscrm
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