Information injection-pump assembly
ZEXEL
101608-6240
1016086240
Rating:
Cross reference number
ZEXEL
101608-6240
1016086240
Zexel num
Bosch num
Firm num
Name
101608-6240
INJECTION-PUMP ASSEMBLY
6D34TL
6D34TL
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
8.4
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
97.5
96.5
98.5
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
89.3
89.3
Boost pressure
mmHg
670
670
Injection quantity adjustment_02
Adjusting point
-
Rack position
5.8+-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
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
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
R1-0.65
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
63
59
67
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_04
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
70
70
75
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
750
750
750
Rack position
R1-0.65
Boost pressure
kPa
37.3
32
42.6
Boost pressure
mmHg
280
240
320
Boost compensator adjustment_02
Pump speed
r/min
750
750
750
Rack position
R1(8.4)
Boost pressure
kPa
76
76
76
Boost pressure
mmHg
570
570
570
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
750+-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)RACK LIMIT
(4)Set idle sub-spring
(5)Boost compensator stroke: BCL
(6)Main spring setting
----------
K=15 BCL=0.65+-0.1mm
----------
----------
K=15 BCL=0.65+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=14deg+-5deg b=21deg+-5deg
----------
----------
a=14deg+-5deg b=21deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
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=14deg
----------
a=(130deg)
----------
aa=14deg
----------
a=(130deg)
Information:
PARTS NEEDED
Qty
Part Number Description
6 1R6573 GASKET
1 2941706 GASKET
6 2941788 SEAL
1 2941790 PIPE
1 2941791 PIPE
1 2941792 PIPE
1 2941793 PIPE
1 2941794 PIPE
1 2941795 PIPE
6 2941803 SEAL-O-RING
6 3264700 INJECTOR GP-F -G
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 2% 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
If your engine is experiencing a lack of power and/or black smoke emissions, complete the following action:
- Replace the six fuel injectors at the time of repair.
Refer to KENR8106, Disassembly and Assembly, for removal/install procedure of the fuel injector groups.
It is recommended that REBE9000, Service Letter, "Product Support Program For Reworking the Fuel Filtration System on Certain 320D and 323D Excavators", be performed at the same time as this Rework Procedure.
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-3500 hrs,
0-24 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
3501-6000 hrs,
25-48 mo 33.0% 33.0% 25.0% 33.0% 25.0% 34.0%
This is a 4.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Have questions with 101608-6240?
Group cross 101608-6240 ZEXEL
Mitsubishi
Mitsubishi
Mitsubishi
Mitsubishi
101608-6240
INJECTION-PUMP ASSEMBLY
6D34TL
6D34TL