101608-6141 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016086141

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-6141 1016086141

Price: query

Buy now
Add to cart Go to cart

Rating:

Buy INJECTION-PUMP ASSEMBLY 101608-6141 zexel genuine, new aftermarket engine parts with delivery

Cross reference number

ZEXEL 101608-6141 1016086141

Zexel num

Bosch num

Firm num

Name

101608-6141

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)Normal (2)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:

This is a 1.5-hour job for Group 2
1) An additional allowance of 4.0 hours can be claimed if the pump needs to be replaced after failing inspection.
2) Should the Dealer not have access to a Bore Scope an allowance of $250 per Dealer is allowed for the purchase of this tool.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
For NACD
Caterpillar Inc.
Attn: Supplier Recovery
Service Claims Room
8201 N. University
Peoria, IL 61615
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
SAFETY - PRODUCT IMPROVEMENT PROGRAM FOR THE INSPECTION AND POSSIBLE REPLACEMENT OF THE FUEL INJECTION PUMP ON CERTAIN TURBOCHARGED 414E, 416E, 420E, AND 430E BACKHOE LOADERS
MODELS INVOLVED - 414E, 416E, 420E, 430E
Dear Caterpillar Product Owner:
The Fuel Injection Pump needs to be inspected and possibly replaced on the products listed below. The existing Fuel Injection Pump can cause an unexpected increase in engine speed which may result in personal injury or death.
You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
Please refer the dealer to their Service Letter dated 08May2008 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed for your added safety and satisfaction.
Caterpillar Inc.
Identification #(s)
Attached to 08May2008 Service Letter
Rework Procedure
Tools required for the inspection of the fuel injection pump are:
17 mm hexagonal socket 3/8" drive.
3/8" drive ratchet wrench with 300 mm extension
Bore Scope with flexible end and ninety degree viewing lens. The Bore Scope has to be capable of being inserted in a 10 mm diameter hole. A 6 mm Bore Scope is recommended for optimium viewing.
1) Before proceeding, first check the serial number shown on the pump identification plate. Image 1.1.1
Image1.1.1
If the machine is identified in the Affected Product and the fuel pump serial number ends with the letter "B" as indicated in image 1.1.1 then the fuel pump should be further inspected.
2) Remove engine compartment door by removing the three bolts holding the door in place using a 13 mm ratchet and socket. Pull the rear of the door away from the machine and then pull the door towards the rear of the machine to remove it from the radiator guard. Image 1.2.1
Image1.2.1
3) Record pump and engine serial number.
Only carry out the following procedure if the pump type number is identified with the "B". (The pumps without the "B" are not affected by this problem).
4) Ensure the area around the fuel return connection is clean. The connection is on the top of the fuel pump toward the front of the engine. Image 1.3.1
Image1.3.1
5) Use a 17 mm X 3/8" drive hexagonal socket, extension 3/8" x 3/8" x 300 mm length and ratchet wrench 3/8" drive to release and remove the return connection fitting.
Note: Be careful not to damage the fitting and o-rings (image 1.4.1), and ensure nothing is