101606-1142 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016061142 me076013

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101606-1142 1016061142

MITSUBISHI ME076013 me076013

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Cross reference number

ZEXEL 101606-1142 1016061142

MITSUBISHI ME076013 me076013

Zexel num

Bosch num

Firm num

Name

101606-1142

ME076013 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 131424-5520

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 11.5

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 69 66.9 71.1

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.9+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 9.2 8.1 10.3

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.5)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 69 68 70

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 82.5 78.5 86.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 47.6 43.6 51.6

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=C92
----------

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

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)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=9.7mm
----------

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:

U.S.A. and Canada
When a problem arises concerning the sale, operation or service of your engine, it will normally be handled by the dealer in your area. The service facility nearest you can be located twenty-four hours a day by calling: 1-800-447-4986.Your satisfaction is a primary concern to Caterpillar and its dealers. If you have a problem that has not been handled to your complete satisfaction, we suggest the steps that follow.Step One
Discuss your problem with a member of management from the dealership.Step Two
When it appears that your problem cannot be readily resolved at the dealer level without additional assistance, use the above telephone number and ask to talk to a Field Service Coordinator. Regular Monday through Friday business hours are from 8:00 a.m. to 4:30 p.m. Central Standard Time (CST).Step Three
If you are still not satisfied, present the engine matter in writing to:Caterpillar Inc.
Manager, Customer Service, Engine Division
Mossville Bldg. A
P.O. Box 600
Peoria, Illinois 61552-0600
When contacting the Manager, Customer Service, please keep in mind that ultimately your problem will likely be resolved at the dealership, using their facilities, equipment, and personnel. Therefore, it is suggested that you follow the above steps in sequence when experiencing a problem.Outside of the U.S.A. and Canada
If a problem arises outside of the U.S.A. and Canada, and cannot be resolved at the dealer level, contact the appropriate Caterpillar subsidiary office.Australia and New Zealand
Caterpillar of Australia Ltd.
1 Caterpillar Drive
Private Mail Bag 4
Tullamarine, Victoria 3043
Australia
Phone: (03) 9339-9333
Fax: (03) 9335-3366
Brazil, Bolivia, and Paraguay
Caterpillar Brasil, Ltda.
Edificio Brasil Interpart
Rua Guararapes, 2064-5 andar, conjunto 2
CEP 04561-004, Sao Paulo, SP
Brasil
Phone: (55) 11-5505-3388
Fax: (55) 11-5505-1647
Central America and Caribbean
Caterpillar Americas Co.
300 South Pine Island Road, Suite 308
Plantation, Florida 33324
U.S.A.
Phone: (954) 472-8204
Fax: (954) 472-4967
China
Caterpillar China Ltd.
One Pacific Place
88 Queensway, Level 8
G.P.O. Box 3069
Hong Kong
Phone: 852-2848-0333
Fax: 852-2848-0440
Ecuador, Colombia, Venezuela, Guyana, and Suriname
Caterpillar Americas Co.
300 South Pine Island Road, Suite 308
Plantation, Florida 33324
U.S.A.
Phone: (954) 475-7202 or 475-7203
Fax: (954) 474-9791
Europe, Africa, and Middle East
Caterpillar Overseas S.A.
76 Route de Frontenex
P.O. Box 6000
1211 Geneva 6
Switzerland
Phone: (22) 849-4444
Fax: (22) 849-4544
Far East
Caterpillar Asia Pte. Ltd.
7 Tractor Road
Jurong, Singapore 627968
Republic of Singapore
Phone: 65-662-8333
Fax: 65-662-8302
Japan
Caterpillar Mitsubishi Ltd.
3700, Tana, Sagamihara-shi
Kanagawa-ken, 229
Japan
Phone: Sagamihara (427) 62-2112
Fax: (427) 62-8542
Mexico
Grupo Financiero Caterpillar Mexico, S.A. de C.V.
Primer piso del Arco Oriente de Arco Bosques
Coporativa,
Bosques del Alisos 45A
Bosques de Las Lomas
Mexico, D.F. 05120
Phone (From within Mexico): 915-259-3389 or
259-3436
Phone (From within the U.S.A.): 011-525-259-3389 or
259-3436
Fax: (309) 675-5364
Peru, Chile, Argentina, and Uruguay
Caterpillar Americas Co.
Edificio Torre Santa Maria
Av. Los Conquistadores 1700
Piso 22B, Oficina B
Santiago, Chile
Phone: (011-562) 231-6354 or 231-0160
Fax: (011-562) 231-0159