101609-9193 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016099193 3436501033

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101609-9193 1016099193

MITSUBISHI-HEAV 3436501033 3436501033

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Cross reference number

ZEXEL 101609-9193 1016099193

MITSUBISHI-HEAV 3436501033 3436501033

Zexel num

Bosch num

Firm num

Name

101609-9193

3436501033 MITSUBISHI-HEAV

INJECTION-PUMP ASSEMBLY
S6K-T 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 131424-5720

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.7 3.65 3.75

Rack position
After adjusting injection quantity. R=A

Beginning of injection position
Drive 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 A

Rack position 8.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 72 71 73

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 85.3 85.3

Boost pressure mmHg 640 640

Injection quantity adjustment_02

Adjusting point -

Rack position 7.2+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 12 10.7 13.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 8.95

Boost pressure kPa 33.3 30.6 36

Boost pressure mmHg 250 230 270

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 9.6

Boost pressure kPa 72 72 72

Boost pressure mmHg 540 540 540

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke (4)Rack difference between N = N1 and N = N2
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K=14 N1=1100r/min N2=700r/min
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=70mm
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a=15deg+-5deg b=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Speed = bb, rack position = cc (sealed at delivery) (3)Normal
----------
aa=25mm bb=0r/min cc=1-0.5mm
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a=21deg+-5deg b=(55deg)

0000001501 I/P WITH LOAD PLUNGER ADJ

Load plunger-equipped pump adjustment 1. Adjust the variation between cylinders and the injection quantity. 2. At Full point A, adjust the pre-stroke to the specified value. 3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
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Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)After adjusting the injection quantity, adjust at rack position bb.
----------
aa=6deg bb=8.6mm
----------
a=(110deg)

Information:

Above 16°C (60°F)
Consult the "Operation" (Operator's) Guide for before starting checks. 1. Turn on the scraper disconnect switch. 2. Move the scraper governor to just past ENGINE STOPPED detent. 3. Push in and turn the start switch to START. Release the switch when the engine starts.
After every 30 seconds of cranking, allow 2 minutes for the starting motor to cool.
4. If the engine oil pressure gauge doesn't register within 10 seconds, push the governor control to the ENGINE STOPPED position to stop the engine. Have corrections made.5. Keep the engine at low idle until the systems are warm.6. Watch all gauges and indicators for correct readings before moving the machine.16°C (60°F) to -12°C (10°F)
1. Follow the steps under "Above 16°C (60°F)."
If the engine does not start after two attempts, use starting fluid. This will prevent excessive battery drain and starting motor overheating.
2. Use starting fluid by pushing the button under the start switch, at 2 second intervals, while cranking the engine. See "Ether Aids" under "Cold Weather Starting Aids."-12°C (10°F) to -26°C (-15°F)
1. Follow the steps under "Above 16°C (60°F)."2. Coolant heaters are required.3. An external battery source may be required if the battery charge is not maintained. See "Boost Starting" under "Cold Weather Starting Aids."4. Starting fluid is required. See "Ether Aids" under "Cold Weather Starting Aids."Below -26°C (-15°F)
1. Follow the steps under "Above 16°C (60°F)."2. Coolant heaters are required.3. An external battery source may be required. See "Boost Starting" under "Cold Weather Starting Aids."4. Starting fluid is required. See "Ether Aids" under "Cold Weather Starting Aids."5. Special lubricants are required. Consult your Caterpillar dealer or refer to Caterpillar Form Number SEBU5338, "Operation, Lubrication and Maintenance Guide for Cold Weather Operation."Starting Aids
Winter Oils
The use of SAE10W viscosity oil in the compartments listed on the chart below will aid in cold weather starting.
Use SAE10W oil only in the temperature ranges indicated.
At lower than above temperatures consult your Caterpillar dealer or refer to the "Operation, Lubrication and Maintenance Guide for Cold Weather Operation," Caterpillar Form Number SEBU5338, for the correct lubricants to use.Ether Aids
Ether is a poison and is flammable.Use it only in well ventilated areas.Use it with care to avoid fires.Avoid breathing the ether vapors, or repeated contact of ether with skin.Do not use ether in environments above 90°C (200°F).
Ether is to be used for cold starting purposes only. Use ether only while cranking the engine. Use it sparingly. Excessive ether can cause piston and ring damage.
Push the button only while cranking the engine.A metered amount of starting fluid (ether) is released each time the button is pushed.After pushing the button, allow 2 seconds before pushing it again.Continue the use of starting fluid every 2 seconds after the engine starts, until it is running smoothly.Batteries
Keep batteries charged to a corrected specific gravity of 1.250 or above. Otherwise, an external electrical source may be required.Boost Starting
Do not allow cable ends to contact each other or the machine.Prevent sparks near the batteries. They could cause battery vapors (hydrogen) to explode.
When