101603-6160 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016036160

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-6160 1016036160

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Service parts 101603-6160 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9830

3. GOVERNOR 105931-2390

4. SUPPLY PUMP 105210-4700

5. AUTOM. ADVANCE MECHANIS 105643-0070

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5990

11. Nozzle and Holder ME035748

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE

105015-5670

15. NOZZLE SET

Include in #1:

101603-6160 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-6772 as _

Cross reference number

ZEXEL 101603-6160 1016036160

Zexel num

Bosch num

Firm num

Name

101603-6160
101606-1122

MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D15 *

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 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 3.6 3.55 3.65

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 10.8

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 60 58.1 61.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 9.3 8.2 10.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.8)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 60 59 61

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 80.5 78.5 82.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 42.5 40.5 44.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 75 85

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1350

Advance angle deg. 2.4 1.9 2.9

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=A77
----------

Speed control lever angle

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

----------
a=10deg+-5deg b=(46deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee. (4)Free (at shipping)
----------
aa=1550r/min bb=(7.1)mm cc=275r/min dd=(8.8)mm ee=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-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=400+-5r/min Ra=9.2mm
----------

Timing setting

(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=12deg
----------
a=(1deg)

Information:

Remove the single tie bolt (6) that is located in the top left corner of the pump by using Tooling (B). Refer to Illustration 7. Only remove the single tie bolt (6). Removing more bolts will result in damage to the pump.
Illustration 2 g01132938
(1) HEUI pump (2) Fuel transfer pump (4) Drive gear (5) 227-5904 O-Ring Seal (6) Tie Bolt (7) Bolts for the fuel transfer pump (8) Tie Bolts (9) Location for service bolt (12) 185-3241 O-Ring Seal
Replace tie bolt (6) with the temporary service bolt (9) that is provided in the service kit.Note: The service bolt that is provided in the kit has an undersized bolt head. The service bolt prevents the body of the HEUI pump from separating during service. Do not remove the service bolt until the fuel transfer pump has been completely reinstalled.
Tighten the service bolt (9) to 10 N m (7.4 lb ft) by using Tooling (C) .Note: Do not place an excessive torque on the service bolt. The aluminum housing of the pump could be damaged.
After installing the service bolt (9) in the top left location, remove the three bolts (7) that fasten the fuel transfer pump to the HEUI pump by using Tooling (A) .
Proceed by removing the remaining three tie bolts (8) by using Tooling (B) .
Separate the fuel transfer pump from the HEUI pump. Refer to Illustration 3.
Illustration 3 g01132944
(1) HEUI pump (2) Fuel transfer pump (9) Service bolt (10) Seals (11) SealInstalling the Fuel Transfer Pump onto the HEUI Pump
Install the two new 239-2402 Seals (10) on the back face of the HEUI pump (1). Refer to Illustration 4.
Illustration 4 g01077898
(1) HEUI pump (10) 239-2402 Seals
Install a new 179-8128 Seal (11) on the fuel transfer pump (2). Refer to Illustration 5. Use 1U-6396 O-Ring Assembly Compound in order to hold the seal in place during assembly. Ensure that the seal is completely seated.
Illustration 5 g01132957
(2) Fuel transfer pump (11) 179-8128 Seal
Do not remove the service bolt. Position the fuel transfer pump on the HEUI pump. Be sure to properly align the drive tang on the fuel transfer pump with the drive slot on the HEUI pump.Note: Align the drive tang of the fuel transfer pump so that the flat end is vertical. Refer to Illustration 5. Align the drive slot in the HEUI pump to a similar vertical orientation by using a flat head screwdriver. Refer to Illustration 6.
Illustration 6 g01132969
Note: Once the fuel transfer pump has been placed onto the HEUI pump, ensure that the face of the fuel transfer pump is flush with the face of the HEUI pump. If the pump faces are not flush, verify the alignment of the drive tang.
Install the three mounting bolts (7) for the fuel transfer pump (2). Tighten