Information injection-pump assembly
ZEXEL
101692-3640
1016923640
Rating:
Cross reference number
ZEXEL
101692-3640
1016923640
Zexel num
Bosch num
Firm num
Name
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
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)
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
3.6
3.55
3.65
Rack position
Point A R=A
Point A R=A
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
11.3
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
49.9
48.9
50.9
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
10.4+-0.
5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
12.5
11.5
13.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT: RAL
(3)Rack difference between N = N1 and N = N2
(4)Damper spring setting: DL
----------
K=14 RAL=17.5+-0.2mm N1=950r/min N2=400r/min DL=7.7+-0.1mm
----------
----------
K=14 RAL=17.5+-0.2mm N1=950r/min N2=400r/min DL=7.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=15deg+-5deg b=32deg+-3deg c=31deg+-5deg
----------
----------
a=15deg+-5deg b=32deg+-3deg c=31deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(30deg)
----------
----------
a=(30deg)
Information:
Lubricant Information
Certain abbreviations follow Society of Automotive Engineers (SAE) J754 nomenclature and some classifications follow SAE J183 abbreviations. SPC is a Caterpillar designation for special synthetic oils, that do not contain viscosity improvers. The MIL-L-46167A specification is U.S.A. Military Specifications.The definitions other than Caterpillar's will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in the Lubricant Viscosities chart in the Maintenance Section.Grease is classified by the National Lubricating Grease Institute (NLGI) based on American Society of Testing & Materials (ASTM D217-68) Worked Penetration characteristics which are given a defined consistency number.Engine Lubricant Specification
Caterpillar has an oil formulation to provide maximum performance and life for your on-highway diesel truck engine. Cat Engine Oils are offered in appropriate viscosity grades to meet the performance and ambient temperature requirements for diesel truck engines.Caterpillar Oil
Caterpillar recommends the following specification to achieve the maximum engine life and performance with your on-highway diesel truck engine.* Caterpillar Engine Oil Cat Diesel Engine Oil-DEO (CF-4)Caterpillar Engine Oil-DEO (CF-4) Part Numbers
The DEO (CF-4) oil is blended in viscosity grades of SAE 10W30 and 15W40. Multi-grade oils lower oil consumption compared to single grades. This oil is also qualified as American Petroleum Institute (API) SG which allows its use in gasoline engine applications requiring this performance rating. Cat Engine Oil is currently offered by Caterpillar for continued refill use. Consult Caterpillar to obtain this oil.Commercial Oils
If oils other than Cat oils are to be used, the following oil specifications provide guidelines for the selection of commercial products.* All oils do not perform equally. Caterpillar recommends the use of API CF-4 performance oil, which has sufficient TBN for fuels with less than 0.5% sulfur. This section assumes a SUPERIOR QUALITY API CF-4 lube oil is used. A lower quality lube oil would require that the oil change intervals be reduced accordingly. * API specifications CF-4, CF-4/SF, or CF-4/SGIf API CF-4 oils are not available, the API CE, CE/SF, or CE/SG may be used with shortened oil change intervals as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S) and infrared analysis.
Failure to follow the commercial oil recommendation for API CF-4 performance oils can cause shortened engine life due to piston carbon deposits, liner bore polish and/or abnormally higher increasing oil consumption.
If API CF-4 or CE oils are NOT AVAILABLE, use local oils of proper viscosity ONLY if oil change interval is shortened to 5000 km (3,100 miles). The oil change interval must also be adjusted by using ROAD CONDITION FACTORS listed in the Maintenance Schedule.Additional Notes
The percentage of sulfur in the fuel will affect the engine oil and oil change interval recommendations. For fuel sulfur effects, the Infrared Analysis and the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature. Refer to Sulfur topic in the Fuel Specification section of this Manual for
Certain abbreviations follow Society of Automotive Engineers (SAE) J754 nomenclature and some classifications follow SAE J183 abbreviations. SPC is a Caterpillar designation for special synthetic oils, that do not contain viscosity improvers. The MIL-L-46167A specification is U.S.A. Military Specifications.The definitions other than Caterpillar's will be of assistance in purchasing lubricants. Recommended oil viscosities can be found in the Lubricant Viscosities chart in the Maintenance Section.Grease is classified by the National Lubricating Grease Institute (NLGI) based on American Society of Testing & Materials (ASTM D217-68) Worked Penetration characteristics which are given a defined consistency number.Engine Lubricant Specification
Caterpillar has an oil formulation to provide maximum performance and life for your on-highway diesel truck engine. Cat Engine Oils are offered in appropriate viscosity grades to meet the performance and ambient temperature requirements for diesel truck engines.Caterpillar Oil
Caterpillar recommends the following specification to achieve the maximum engine life and performance with your on-highway diesel truck engine.* Caterpillar Engine Oil Cat Diesel Engine Oil-DEO (CF-4)Caterpillar Engine Oil-DEO (CF-4) Part Numbers
The DEO (CF-4) oil is blended in viscosity grades of SAE 10W30 and 15W40. Multi-grade oils lower oil consumption compared to single grades. This oil is also qualified as American Petroleum Institute (API) SG which allows its use in gasoline engine applications requiring this performance rating. Cat Engine Oil is currently offered by Caterpillar for continued refill use. Consult Caterpillar to obtain this oil.Commercial Oils
If oils other than Cat oils are to be used, the following oil specifications provide guidelines for the selection of commercial products.* All oils do not perform equally. Caterpillar recommends the use of API CF-4 performance oil, which has sufficient TBN for fuels with less than 0.5% sulfur. This section assumes a SUPERIOR QUALITY API CF-4 lube oil is used. A lower quality lube oil would require that the oil change intervals be reduced accordingly. * API specifications CF-4, CF-4/SF, or CF-4/SGIf API CF-4 oils are not available, the API CE, CE/SF, or CE/SG may be used with shortened oil change intervals as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S) and infrared analysis.
Failure to follow the commercial oil recommendation for API CF-4 performance oils can cause shortened engine life due to piston carbon deposits, liner bore polish and/or abnormally higher increasing oil consumption.
If API CF-4 or CE oils are NOT AVAILABLE, use local oils of proper viscosity ONLY if oil change interval is shortened to 5000 km (3,100 miles). The oil change interval must also be adjusted by using ROAD CONDITION FACTORS listed in the Maintenance Schedule.Additional Notes
The percentage of sulfur in the fuel will affect the engine oil and oil change interval recommendations. For fuel sulfur effects, the Infrared Analysis and the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature. Refer to Sulfur topic in the Fuel Specification section of this Manual for