101606-6380 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016066380 me076283m

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101606-6380 1016066380

MITSUBISHI ME076283M me076283m

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Cross reference number

ZEXEL 101606-6380 1016066380

MITSUBISHI ME076283M me076283m

Zexel num

Bosch num

Firm num

Name

101606-6380

ME076283M MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D15T2 * 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 4.2 4.15 4.25

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 12.5

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 90.5 87.8 93.2

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. 10.2 8.7 11.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.5)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 90.5 89.5 91.5

Basic *

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.25

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 101.8 97.8 105.8

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 65 105

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 350 350 350

Rack position R2-0.9

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

Boost compensator adjustment_02

Pump speed r/min 350 350 350

Rack position R2-0.6

Boost pressure kPa 12.7 11.4 14

Boost pressure mmHg 95 85 105

Boost compensator adjustment_03

Pump speed r/min 350 350 350

Rack position R2(R1+0. 75)

Boost pressure kPa 21.3 21.3 21.3

Boost pressure mmHg 160 160 160

Timer adjustment

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1225

Advance angle deg. 1.5 1 2

Timer adjustment_03

Pump speed r/min 1300

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=D59 BCL=0.9+-0.1mm
----------

Speed control lever angle

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

----------
a=18.5deg+-5deg b=(41deg)+-3deg

Stop lever angle

N:Pump normal 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).
----------
aa=6.5-0.5mm bb=275r/min cc=6.5-0.5mm
----------
a=11.5deg+-5deg b=27deg+-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=400r/min Ra=9.2+-0.1mm
----------

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=11deg
----------
a=(1deg)

Information:

Start By:a. remove timing gear cover
Do not disconnect the air line from the air compressor governor until the air pressure is zero.
1. Loosen the bleed valves, and release the air pressure in the air tank. 2. Disconnect the lines from air compressor (1), and remove the air compressor. 3. Remove sleeve (2) from air compressor drive gear (3). 4. Remove the nut and washer that holds the air compressor drive gear to the air compressor. Use tooling (A) to remove air compressor drive gear (3) from the air compressor. 5. Remove nuts (4) and plate (5). Remove gear assembly (6) from the shaft. 6. If damaged, remove bearing (7) from gear assembly (6) with tooling (B) and a press. 7. Remove three nuts (8) and the washers from the adapter assembly studs. 8. Remove adapter assembly (9) from the timing gear plate. 9. Remove shaft (10), O-ring seal (11) and sleeve (12) from the adapter assembly.Install Air Compressor And Accessory Drive
1. Install sleeve (12) into the adapter assembly.2. Install shaft (10) and O-ring seal (11) on the adapter assembly. 3. Put adapter assembly (9) in position on the timing gear plate. fasten it with the three nuts and washers. 4. Install the bearing in gear assembly (6) with tooling (A) and a press. Install the bearing until it is 1.5 0.5 mm (.06 .02 in.) below the surface of the gear as shown. 5. Put gear assembly (6) in position on the shaft.6. Put plate (5) in position, and install three nuts (4) to hold it. 7. Put air compressor drive gear (3) in position on the air compressor shaft, and install the washer and nut (13). Tighten the nut to a torque of 200 25 N m (150 18 lb.ft.). Tap the gear with a hammer and tighten nut again to a torque of 200 25 N m (150 18 lb.ft 8. Install sleeve (2) on gear (3). 9. Put a gasket in position on air compressor (1) and install the air compressor on the timing cover plate.End By:a. install timing gear cover