101601-6932 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016016932 me036993s


 

Information injection-pump assembly

ZEXEL 101601-6932 1016016932
MITSUBISHI ME036993S me036993s
101601-6932 INJECTION-PUMP ASSEMBLY
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Service parts 101601-6932 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-8370
3. GOVERNOR 105490-4450
4. SUPPLY PUMP 105210-4661
5. AUTOM. ADVANCE MECHANIS 105643-0010
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-4632
11. Nozzle and Holder ME036780
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105030-4990
14. NOZZLE 105015-4220
15. NOZZLE SET

Include in #1:

101601-6932 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-6932 1016016932
MITSUBISHI ME036993S me036993s


Zexel num
Bosch num
Firm num
Name
101601-6932 
 
ME036993S  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D15 * 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   131424-3720
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   157 157 157
Tester oil delivery pressure kgf/cm2   1.6 1.6 1.6
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   4.2 4.15 4.25
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   -
Rack position   9.4
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   74.5 72.3 76.7
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   D
Rack position   7.1+-0.5
Pump speed r/min   500 500 500
Each cylinder's injection qty mm3/st.   11 7.7 14.3
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(9.4)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   74.5 73.5 75.5
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(9.4)
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   83.9 80.6 87.2
Difference in delivery mm3/st.   6.6 6.6 6.6
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   7.7+-0.5
Pump speed r/min   275 275 275
Each cylinder's injection qty mm3/st.   11 9.4 12.6
Fixing the rack   *
Remarks
(check)
 
Timer adjustment
Pump speed r/min   1200
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1350
Advance angle deg.   2.4 1.9 2.9
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-6932
N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Excess fuel setting for starting: SXL
----------
DL=6-0.2mm SXL=R1+1+0.8mm
----------

Speed control lever angle

Test data 101601-6932
F:Full speed
----------

----------
a=10deg+-5deg

0000000901

Test data 101601-6932
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=11deg+-5deg b=24deg+-3deg

Stop lever angle

Test data 101601-6932
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=2.5mm bb=21mm
----------
a=71deg+-5deg b=56deg+-5deg c=(9.5deg)

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=410r/min Ra=7.3mm
----------

Timing setting

Test data 101601-6932
(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(0deg)




Information:


Adjustment of the fuel system outside Caterpillar specified limits will not improve fuel efficiency and could result in damage to the engine.
If you feel you have a vehicle performance problem, first consider the impact of vehicle efficiency and operating characteristics (vehicle speed, design, etc.), on power demand before questioning engine performance.In the case of poor fuel economy, the engine is not likely to be the cause without the presence of excessive exhaust smoke and/or a significant loss of power.If you feel you have a valid engine performance problem, contact an authorized Caterpillar dealer for assistance. If your engine is under warranty, then the Caterpillar warranty or extended service coverage (if purchased) will cover the cost of resolving a valid engine performance deficiency. Refer to the Warranty Section in this publication and your Caterpillar dealer for details.However, if the engine is not found at fault, all costs incurred will be the responsibility of the owner.Performance Analysis Report (PAR)
PAR complements a good preventive maintenance program. PAR analysis can monitor the condition of your engine and to determine if your engine is operating at peak efficiency.PAR reflects the results of various tests normally conducted by your Caterpillar dealer for the purpose of:* confirming your engine is operating efficiently and within specification.* identifying potential problems.* determining components or systems that should be adjusted, replaced, etc.Approximately eighty to 85% of your truck engine's total operation and maintenance cost is the cost of fuel. Therefore, substantial cost reductions can be achieved by keeping your engine operating at peak efficiency. Fuel consumption and performance of your engine is affected by vehicle specifications, how it is operated and condition of the engine. Each plays an important part in minimizing your total owner and operating cost.Do not attempt to use PAR until the first engine oil change. This allows for sufficient break-in of the engine, drive train and tires. Fuel rate and turbocharger boost will be measured under load at five engine speeds and compared to factory specifications. Fuel rate and boost are the primary indicators of your engine's performance and the analysis of this data will help pinpoint potential problems faster.Wheel horsepower (kW) will also be recorded during the initial PAR test to establish your truck's exact wheel horsepower (kW) over its full operating range. This power can then be compared to the power of subsequent PAR tests. Power available at the wheels is not only the result of the condition of the engine, but also the transmission, drive axle(s), brakes, tires and engine drive accessories.Consult your Caterpillar dealer for complete information and assistance in establishing a PAR program for your engine.Refer to Form LEDT4211, PEDP0026 and/or Performance Troubleshooting Manual, Form SENR4249 or your Caterpillar dealer for more information on PAR.Contact your nearest Caterpillar dealer for information on PAR and the location of the nearest, approved dynamometer.

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