101608-6150 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016086150

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-6150 1016086150

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Cross reference number

ZEXEL 101608-6150 1016086150

Zexel num

Bosch num

Firm num

Name

101608-6150

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 11.8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 142.5 141.5 143.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 73.3 73.3

Boost pressure mmHg 550 550

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

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 10

Boost pressure kPa 21.3 18.6 24

Boost pressure mmHg 160 140 180

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 11.2

Boost pressure kPa 60 53.3 66.7

Boost pressure mmHg 450 400 500

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)Set idle sub-spring (3)Main spring setting (4)Boost compensator stroke: BCL
----------
K=8 BCL=1.2+-0.1mm
----------

Speed control lever angle

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

----------
a=(20deg)+-5deg b=(3deg)+-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:

PARTS NEEDED
Qty
Part Number Description
6 10R7225 INJECTOR GP-FUEL
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 18% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Take the following actions before or after a failure occurs on one or more injectors in any of the machines listed in this service letter.
- If one or more injectors fail it may be necessary to replace up to 6 injectors at the time of repair.
There will be situations when all 6 injectors do not have to be replaced. Refer to next paragraph to determine which injectors should be replaced.
- If an injector repair has previously been performed after approximately 01Oct07 on any of the listed machines, only the injectors that were not replaced at that time should be replaced. This should further be verified by comparing the injector serial numbers in the engine to a range of 3B115776403B to 3B11676551F9. Disregard the first and last two characters in the serial number (in this case "3B" and "3B" in the first serial number and "3B" and "F9" in the second serial number). The reason for verifying the serial number range is due to a batch change of the internal part that is failing. The change was made after serial number 3B11676551F9.
Only injectors falling within the range of 11577640-11676551 should be replaced.
- If the suspect injector can not be identified by using the automatic cylinder cutout test use the two methods below.
- First, run a manual cylinder cutout test at a high engine speed with some load on the engine. When the injector that has failed is cutout, the sound of the engine should be more normal as opposed to the loud knocking heard when the failed injector is active. The second method is to unplug the wiring harness at the valve cover base that sends current to the injector solenoids as well as the harness connection for the injection actuation pressure sensor. By making these disconnections, the fuel injectors will not fire and the HEUI pump will go to maximum actuation pressure. Then remove the valve cover and crank the engine. The injectors that have failed should expel more oil (from the HEUI System) than those that are not failed.
-Refer to RENR9579 for removal/install procedure of the unit injector.
-The serial number of all injectors replaced in a machine covered under this service letter must be documented in the claims story.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-1000 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
The serial number of any injector(s) replaced in a machine covered under this service letter must be documented in the claims story. Only injectors with serial numbers between 11577640-11676551 (see action required for explanation on how to decode injector serial number) will be