101603-6540 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016036540

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-6540 1016036540

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Cross reference number

ZEXEL 101603-6540 1016036540

Zexel num

Bosch num

Firm num

Name

101603-6540
101603-6541

MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D14T *

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 2.95 3.05

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 12.1

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 88 85.4 90.6

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. 10.5 9 12

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.1)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 88 87 89

Basic *

Fixing the lever *

Boost pressure kPa 49.3 49.3

Boost pressure mmHg 370 370

Injection quantity adjustment_04

Adjusting point C

Rack position (R1-0.8)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 67 65 69

Fixing the lever *

Boost pressure kPa 18.7 18.7 18.7

Boost pressure mmHg 140 140 140

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 90 130

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-1.1

Boost pressure kPa 13.3 13.3 13.3

Boost pressure mmHg 100 100 100

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position (R1-0.8)

Boost pressure kPa 18.7 17.4 20

Boost pressure mmHg 140 130 150

Boost compensator adjustment_03

Pump speed r/min 700 700 700

Rack position R1(12.1)

Boost pressure kPa 36 29.3 42.7

Boost pressure mmHg 270 220 320

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 1300

Advance angle deg. 1.6 1.1 2.1

Timer adjustment_04

Pump speed r/min 1400

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B44 BCL=1.1+-0.1mm
----------

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=(41deg)+-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 (non-injection rack position). Confirm non-injection. (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=(7.5)mm bb=275r/min cc=(9)mm dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg

0000001201

I:Idle F:At operation, hold it in the full speed position. (1)Rack position = aa, speed = bb
----------
aa=8.4mm bb=1490r/min
----------
a=15deg+-5deg b=36deg+-3deg

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=15deg
----------
a=(0deg)

Information:

Specifications
Illustration 42 g03135400
Table 13
Fuel Injection Pump Camshaft
Model Dimension A Dimension B Dimension C Dimension D Dimension E
3064
3066 40.72 0.25 mm (1.603 0.010 inch) 20.003 0.005 mm (0.7875 0.0002 inch) 11.13 0.25 mm (0.438 0.010 inch) 16.955 0.005 mm (0.6675 0.0002 inch) 16.26 0.25 mm (0.640 0.010 inch) Note: All sprayed edges should be rounded with a 0.795 mm (0.0313 inch) radius.Storage Procedures
Proper protection of the components from corrosion is important. Corrosion will start in as little as one hour after the components have been cleaned.When the components will not be inspected for one hour or less the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil. The components should be individually wrapped to prevent contamination, and should be stored in a protected area to avoid damage. See Illustration 43.When the components will not be inspected in two days or more the components should be coated with a rust or corrosion inhibitor or coated with clean engine oil and should be placed in a container which is clean and structurally solid. The container should be covered or wrapped in plastic to prevent damage and contamination to the components. See Illustration 44.Refer to SEHS9031Special Instruction, "Storage Procedure for Caterpillar Products" for more information.
Illustration 43 g06278538
Example of protection for a component that is stored for a shorter term
Illustration 44 g06278539
Example of protection for a component that is stored for a longer period