101603-1050 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016031050 me036994


 

Information injection-pump assembly

ZEXEL 101603-1050 1016031050
MITSUBISHI ME036994 me036994
101603-1050 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101603-1050 1016031050
MITSUBISHI ME036994 me036994


Zexel num
Bosch num
Firm num
Name
101603-1050 
 
ME036994  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.   83 80.5 85.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   D
Rack position   7.5+-0.5
Pump speed r/min   500 500 500
Each cylinder's injection qty mm3/st.   11.6 8.1 15.1
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.   83 82 84
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.   90.6 87 94.2
Difference in delivery mm3/st.   7.2 7.2 7.2
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   7.9+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   11.6 9.9 13.3
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 101603-1050
N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Set the main spring (after setting the idle sub spring).
----------
K=6
----------

Speed control lever angle

Test data 101603-1050
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=48deg+-5deg b=30deg+-5deg

Stop lever angle

Test data 101603-1050
N:Pump normal S:Stop the pump.
----------

----------
a=19deg+-5deg b=53deg+-5deg

Timing setting

Test data 101603-1050
(1)Pump vertical direction (2)Position of gear mark '2' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(80deg)




Information:


26Feb2020
U-93
A-70
D-86
O-82
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN 471-6029 DEF INJECTOR AND MOUNTING GROUPS FROM DEALER PARTS STOCK
108I 7750 PI70799
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
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
31May2020
PROBLEM
A defined batch of existing 471-6029 DEF Injector and Mounting Groups can fail under certain conditions.
ACTION REQUIRED
Inspect all 471-6029 DEF Injector and Mounting Groups in dealer parts stock.
Open the packaging and visually inspect the DEF injector.
If the DEF injector's upper body molding mark is an A or B, then the DEF injector is acceptable to use. Repackage the DEF injector and mark the packaging as inspected per this program and place the part back into dealer parts stock.
If the DEF injector's upper body molding mark is a 1 or 2, then remove the part from dealer parts stock. Refer to the Parts Disposition.
Image 1 shows the molding marks and location.
Image1
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock.
PARTS DISPOSITION
NACD:
Hold all 471-6029 DEF Injector and Mounting Groups removed from dealer parts stock for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.
EAME, LACD, and APD:
Hold all 471-6029 DEF Injector and Mounting Groups removed from dealer parts stock for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.

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