101491-1002 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014911002 me016095

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-1002 1014911002

MITSUBISHI ME016095 me016095

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Cross reference number

ZEXEL 101491-1002 1014911002

MITSUBISHI ME016095 me016095

Zexel num

Bosch num

Firm num

Name

101491-1002

ME016095 MITSUBISHI

INJECTION-PUMP ASSEMBLY
4D31T * K

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 131424-5620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.5 3.45 3.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 11.45

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 66.5 65.5 67.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10 8.7 11.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.45 )

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 66.5 65.5 67.5

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 75.5 73.5 77.5

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.35

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 47.5 45.5 49.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position 14.8+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 66 66 71

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-0.35

Boost pressure kPa 20 18.7 21.3

Boost pressure mmHg 150 140 160

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(11.45 )

Boost pressure kPa 30.7 24 37.4

Boost pressure mmHg 230 180 280

Timer adjustment

Pump speed r/min 1400

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1650

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=K14 BCL=0.35+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=26deg+-5deg b=42deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Use the hole at R = aa (2)Free (at delivery) (3)Rack position corresponding to bb (4)Set the stopper bolt so that speed = cc and rack position = dd and confirm non-injection. (5)After setting the stopper bolt, confirm non-injection at speed ee. Rack position = ff or less.
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=(8)mm
----------
a=25deg+-5deg b=15deg+-5deg c=33deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=350r/min Ra=9.5+-0.1mm
----------

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=10deg
----------
a=(130deg)

Information:

The information supplied in this service letter may not be valid after the termination date of this program. Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
Termination Date
August 31, 1997Problem
0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 need to be removed from Parts Stock.Action Required
Inspect all 0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 from Parts Stock.
The date code can be located below the part name and above the part number on part number tag attached to the box. The date code is formatted as DDMMYYXXX (example; a box marked with a date code of 150195068 would indicate a part manufactured on January 15, 1995 at plant number 068).
If the injector is no longer in the original box, use the date code engraved on the top of the unit injector tappet. It is in the "NUMERAL KOD" format. The code consists of the month and the year.
Where the numbers for the months and years are coded as follows:
January 1997 ... NUDKFebruary 1997... NMDKMarch 1997 ... NEDKApril 1997 ... NRDKTo inspect the injectors, push the rack bar in against the trim adjustment screw (the fuel off position). On the flat "D" section of the rack bar extending out of the injector and beyond the rack teeth, inspect for a shinny grooved machine mark completely across the flat surface and parallel with the rack teeth. This mark is caused by the plunger gear contacting the flat of the rack bar If the mark is present, the injector should be returned to Caterpillar.
Service Claim Allowances
Submit one claim for all 0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 removed from Parts Stock.
MEPS dealers are reimbursed for recalled Parts Stock by returning the affected Parts Stock to their administering Caterpillar dealer for replacement.
Parts Disposition
All injectors removed from Parts Stock are to be returned as cores for remanufacturing.
U.S. and Canadian Dealers
Return all 0R0906, 0R1756, 0R1758, 0R2921, 0R2922, 0R2923, 0R2924, 0R2925, 0R3051, and 0R3052 Remanufactured Unit Injectors with date codes between January 01, 1997 and April 30, 1997 that are removed from Parts Stock and a copy of the claim to:
Caterpillar Inc.
Attn: Bill Harland - Warranty Review
501 Cardinal Drive
Corinth, MS 38834
All Other Dealers
Handle the parts in accordance with your Warranty Bulletin on Remanufactured Engines and Components, refer to the topic "Disposition of the Core Under Warranty".