101603-6440 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016036440 me076003


 

Information injection-pump assembly

ZEXEL 101603-6440 1016036440
MITSUBISHI ME076003 me076003
101603-6440 INJECTION-PUMP ASSEMBLY
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Service parts 101603-6440 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-9690
3. GOVERNOR 105931-3330
4. SUPPLY PUMP 105210-4700
5. AUTOM. ADVANCE MECHANIS 105643-0180
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6780
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6(220)
13. NOZZLE-HOLDER 105031-3900
14. NOZZLE 105015-6440
15. NOZZLE SET

Include in #1:

101603-6440 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101603-6440 1016036440
MITSUBISHI ME076003 me076003


Zexel num
Bosch num
Firm num
Name
101603-6440 
 
ME076003  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D16 * 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   131424-5520
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   3.3 3.25 3.35
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   11.4
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   54.5 52 57
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   D
Rack position   8.7+-0.5
Pump speed r/min   500 500 500
Each cylinder's injection qty mm3/st.   7.6 5.9 9.3
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.4)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   54.5 53.5 55.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.4
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   79.8 75.8 83.8
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1(11.4)
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   48.5 44.5 52.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   14.3+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   73 63 83
Fixing the lever   *
Rack limit   *
Injection quantity adjustment_07
Adjusting point   H
Rack position   9.5+-0.5
Pump speed r/min   275 275 275
Each cylinder's injection qty mm3/st.   8.7 7 10.4
Fixing the rack   *
Remarks
(check)
 
Timer adjustment
Pump speed r/min   900--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   850
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1200
Advance angle deg.   2.7 2.2 3.2
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-6440
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B07
----------

Speed control lever angle

Test data 101603-6440
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=33deg+-5deg b=41deg+-3deg

Stop lever angle

Test data 101603-6440
N:Engine manufacturer's normal use S:Stop the pump. (1)Free (at shipping) (2)Rack position = approximately aa. (3)Set the stopper bolt at speed = rated point and rack position = bb. Confirm non-injection. (4)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=17.4mm bb=6.7mm cc=275r/min dd=(8.3)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-5deg

Timing setting

Test data 101603-6440
(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=16deg
----------
a=(1deg)




Information:


Cat does not warrant the quality or performance of non-Cat fluids.
Do NOT mix brands or types of SCA. Do NOT mix SCAs and extenders.Failure to follow the recommendations can result in shortened cooling system component life.
Use Only Approved SCAs. Conventional coolants require the maintenance addition of SCA throughout their expected life. Do NOT use an SCA with a coolant unless specifically approved by the coolant supplier for use with their coolant. It is the responsibility of the coolant manufacturer to ensure compatibility and acceptable performance.Failure to follow the recommendations can result in shortened cooling system component life.
Follow the maintenance information provided in the “Coolant and General Maintenance Recommendations” section in this Special Publication.Select a commercial diesel engine antifreeze coolant that meets all the requirements given in Table 1. The table contains the requirements for coolant to meet the published service intervals.The provided requirements are applicable to finished coolants and not for the concentrates. When concentrated coolant/antifreeze is mixed, Cat recommends mixing the concentrate with distilled water or with deionized water. If distilled water or deionized water is not available, water which has the required properties may be used. For the water properties, refer to this Special Publication, "General Coolant Information" article.Coolant/antifreezes for heavy-duty applications that meet "ASTM D6210" do not require treatment with SCA at the initial fill. Use the recommended 1:1 or higher concentration with recommended water. Treatment with SCA is required on a maintenance basis.The SCA manufacturer is responsible for ensuring the SCA is compatible with water meeting the “Caterpillar Minimum Acceptable Water Quality Requirements” as found in this Special Publication, and "ASTM D6210-08, Table X1.1". The coolant manufacturer and the SCA manufacturer are responsible to ensure that the products will not cause cooling system harm.Do not mix brands or types of coolants with different brands or types of SCA or extender.If using non Cat coolants, refer to the coolant manufacturer for information on a compatible SCA.Treat the compatible commercial coolant with 3 to 6 percent Cat SCA by volume. Maintain a 3 to 6 percent concentration level of SCA in the cooling system. For more information, refer to this Special Publication, "Conventional Coolant/Antifreeze Cooling System Maintenance" article.
Table 1
Technical Requirements for Commercial Diesel Engine Antifreeze Coolants
Specifications ASTM D6210-08
Additional Requirements Silicon: 100 ppm minimum to 275 ppm maximum
Nitrites: maintained at 1200ppm (70 grains/US gal) minimum to 2400 ppm (140 grains/US gal) maximum
Cat SCA at 3 to 6 percent (if Cat SCA is added)
Maintenance ASTM D6210-08 Add compatible SCA at maintenance intervals
Clean and flush the cooling system at drain intervals

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