101608-6180 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016086180

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-6180 1016086180

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Cross reference number

ZEXEL 101608-6180 1016086180

Zexel num

Bosch num

Firm num

Name

101608-6180

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

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 9.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 78 77 79

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.5+-0.5

Pump speed r/min 475 475 475

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.

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 70 75

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).

Timer adjustment_03

Pump speed r/min 750+-25

Advance angle deg. 0 0 0

Remarks
Finish

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)Supplied with torque spring not set. (4)RACK LIMIT (5)Set idle sub-spring (6)Main spring setting
----------
K=12
----------

Speed control lever angle

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

----------
a=(4deg)+-5deg b=(18deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=26.5deg+-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=16deg
----------
a=(130deg)

Information:

Information Release Memo REM03-10
Reman
May 2003 REMANUFACTURED FUEL INJECTOR FOR VARIOUS 3500 GENSET, MACHINE AND MARINE APPLICATIONS Announcement The Caterpillar Remanufactured Products Group announces the expansion of the remanufactured injector product line to include coverage for various 3500 Genset, Machine and Marine applications. Coverage The addition of this Reman injector provides dealers with an additional repair option to support various 3500 Genset, Machine and Marine applications. Coverage is extensive so please consult your NPR or Reman Cross Reference for exact model coverage. 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. Features
All critical engineering changes and updates included
Worldwide availability through Caterpillar? parts distribution system
Backed by Cat warranty Benefits
Improved reliability and performance
Customer access regardless of location
Consistent support Core Acceptance Core Acceptance Criteria for Caterpillar Remanufactured injectors is simple, visual, and requires no special tools. Full core credit is issued when the core is complete, fully assembled, and has an acceptable part number. 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 Customer Satisfaction Hot Line also toll free at (888) 88-REMAN or use our E-mail address--Reman_Help.
PELJ0170 CATERPILLAR? ?2003 Caterpillar