Information injection-pump assembly
ZEXEL
101603-6321
1016036321
MITSUBISHI
ME035596
me035596
Rating:
Service parts 101603-6321 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME035748
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Cross reference number
ZEXEL
101603-6321
1016036321
MITSUBISHI
ME035596
me035596
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor 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
-
Rack position
11
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
-
Rack position
10+-0.5
Pump speed
r/min
275
275
275
Each cylinder's injection qty
mm3/st.
10
8.9
11.1
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11)
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+0.5
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
80
76
84
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.25
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
43.7
39.7
47.7
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
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
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=C16
----------
----------
T1=C16
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=18.5deg+-5deg b=42deg+-3deg
----------
aa=40mm
----------
a=18.5deg+-5deg b=42deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Set the stopper bolt at speed = rated point and rack position = aa and confirm non-injection (non-injection rack position).
(2)After setting the stopper bolt , confirm non-injection at pump speed bb. Rack position = cc (non-injection rack position).
(3)Rack position = approximately dd
(4)Free (at shipping)
----------
aa=(7)mm bb=275r/min cc=(8)mm dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg
----------
aa=(7)mm bb=275r/min cc=(8)mm dd=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
----------
----------
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)
----------
aa=12deg
----------
a=(1deg)
Information:
Do not use the same vacuum sampling pump for extracting oil samples that is used for extracting coolant samples.A small residue of either type sample may remain in the pump and may cause a false positive analysis for the sample being taken.Always use a separate pump for oil sampling and a separate pump for coolant sampling.Failure to do so may cause a false analysis which could lead to customer and dealer concerns.
New Systems, Refilled Systems, and Converted Systems
Perform an S O S coolant analysis (Level 2) at the following maintenance intervals.
Initial 500 service hours
Every Year or every 2000 hours, whichever comes firstPerform this analysis at the interval that occurs first for new systems, for refilled systems, or for converted systems that use Cat ELC (Extended Life Coolant) or use Cat DEAC (Diesel Engine Antifreeze/Coolant). This 500 hour check will also check for any residual cleaner that may have contaminated the system.Recommended Interval for S O S Services Coolant Sample
The following table contains the recommended sampling interval for all coolants that meet Cat EC-1 (Engine Coolant specification - 1). This is also the recommended sampling interval for all conventional heavy-duty coolant/antifreeze.The Level 2 Coolant Analysis should be performed if a problem is suspected or identified.
Table 1
Recommended Interval
Type of Coolant Level 1 Level 2
Cat DEAC
and Conventional Heavy-Duty Coolants Every 250 hours Yearly
Cat ELC
and Commercial EC-1 coolants Optional or every 500 hours Yearly or every 500 hours Note: Check the SCA (Supplemental Coolant Additive) of the conventional coolant at every oil change or at every 250 hours. Perform this check at the interval that occurs first.Refer to your machine OMM for recommendations specific to your machine.S O S Services Coolant Analysis (Level 1)
A coolant analysis (Level 1) is a test of the properties of the coolant.The following properties of the coolant are tested:
Glycol concentration for freeze protection and boil protection
Ability to protect from erosion and corrosion
pH
Conductivity
Visual analysis
Odor analysisThe results are reported, and appropriate recommendations are made.S O S Services Coolant Analysis (Level 2)
A coolant analysis ( Level 2) is a comprehensive chemical evaluation of the coolant. This analysis is also a check of the overall condition of the cooling system.The S O S coolant analysis ( Level 2) has the following features:
Full coolant analysis (Level 1)
Identification of metal corrosion and of contaminants
Identification of buildup of the impurities that cause corrosion
Identification of buildup of the impurities that cause scaling
Determination of the possibility of electrolysis within the cooling system of the engineThe results are reported, and appropriate recommendations are made.For more information on S O S coolant analysis, consult your Caterpillar dealer.