101608-6270 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016086270

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101608-6270 1016086270

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Cross reference number

ZEXEL 101608-6270 1016086270

Zexel num

Bosch num

Firm num

Name

101608-6270

INJECTION-PUMP ASSEMBLY
6D16TL

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)
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 11.4

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 126.5 125.5 127.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 72 72

Boost pressure mmHg 540 540

Injection quantity adjustment_02

Adjusting point C

Rack position 7.7+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 8.5 7 10

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 R1-1.45

Boost pressure kPa 14.7 12 17.4

Boost pressure mmHg 110 90 130

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(11.4)

Boost pressure kPa 58.7 52 65.4

Boost pressure mmHg 440 390 490

Timer adjustment

Pump speed r/min (1050)

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

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)Target notch: 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=9 BCL=1.45+-0.1mm
----------

Speed control lever angle

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

----------
a=19deg+-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:

For serial number specific information, please see SISWEB.
Features and Benefits
Cat Reman products 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 products. Cat Reman parts provide immediate, off-the-shelf availability at a fraction of the new price.
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
Backed by Caterpillar parts warranty
Consistent support
Core Acceptance
Core Acceptance Criteria for Cat Reman parts is simple, visual, and requires no special tools. Please consult the applicable Core Acceptance Criteria for each product for complete details. Core Acceptance Criteria can be found at catreman.cat.com/cac.
Unit Injectors Electronic - SELD0226-01
Warranty
Please consult the appropriate Caterpillar parts warranty statement for your area.
Core Management
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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://catreman.cat.com. If you have any questions regarding core return processing, feel free to call Corinth toll free at (800) 537-2928. Outside the US please refer to the Core section of the Reman website for appropriate contact information for your region.
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