Information injection-pump assembly
ZEXEL
101609-9222
1016099222
MITSUBISHI-HEAV
3436501052
3436501052
Rating:
Service parts 101609-9222 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
101609-9222
as INJECTION-PUMP ASSEMBLY
Include in #2:
104132-6050
as _
Cross reference number
ZEXEL
101609-9222
1016099222
MITSUBISHI-HEAV
3436501052
3436501052
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
After adjusting injection quantity. R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
6.9
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
38.7
37.7
39.7
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.4+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
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)Set idle sub-spring
(4)Main spring setting
(5)Set the torque spring.
(6)Rack difference between N = N1 and N = N2
----------
K=15 N1=1100r/min N2=700r/min
----------
----------
K=15 N1=1100r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=19deg+-5deg b=19deg+-5deg
----------
----------
a=19deg+-5deg b=19deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Contacts outer boss.
(2)Contacts inner boss.
(3)Use the hole at R = aa
(4)Normal
----------
aa=60mm
----------
a=53deg+-5deg b=26.5deg+-5deg c=(9deg)
----------
aa=60mm
----------
a=53deg+-5deg b=26.5deg+-5deg c=(9deg)
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.
----------
----------
----------
----------
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=6.9mm
----------
a=(110deg)
----------
aa=6deg bb=6.9mm
----------
a=(110deg)
Information:
Ejector Guide Rollers
(631 & 637)
Adjust
1. The ejector should operate freely without binding. To adjust the guide rollers, loosen the roller shaft clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller. 3. Tighten the clamping bolt. Clearance between the guide rollers and the scraper bowl should be 3.00 to 20.00 mm (.118 to .787 in).Ejector Carrier Rollers
(631 & 637)
Adjust
1. The ejector should operate freely without dragging. To adjust the carrier rollers, loosen the clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller.3. Tighten the clamping bolt. Clearance between the bottom of the ejector and the bottom of the bowl should be 1.0 to 13.0 mm (.04 to .50 in).Ejector Support Rollers
(631 & 637)
Adjust
1. The ejector should operate freely without dragging. To adjust the carrier rollers, loosen the clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller. 3. Tighten the clamping bolt. The distance between rollers, outside to outside, should be .00 to 6.00 mm (.00 to .236 in) less than the narrowest dimension between the roller guide tracks.Refer to the Service Manual for your machine or contact your Caterpillar dealer for the correct adjustment procedure.Ejector Carriage Rollers
(639)
Adjust
Do not get under the push frame unless the front engine is stopped and the ejector floor is blocked.
1. Install pin in the position that will block movement of the carriage.See "Blocking the Ejector Floor Closed" in the "Safety" section of the Operation (Operator's) Guide. 2. The carriage should operate freely without binding. To adjust the carriage rollers, loosen the roller shaft clamping bolt. 3. Turn the roller (eccentric) shaft to position the rollers. 4. Tighten the clamping bolt. The distance between rollers, outside to outside, should be .00 to 1.50 mm (.00 to .060 in) less than the narrowest dimension between the guide tracks on the push frame.
(631 & 637)
Adjust
1. The ejector should operate freely without binding. To adjust the guide rollers, loosen the roller shaft clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller. 3. Tighten the clamping bolt. Clearance between the guide rollers and the scraper bowl should be 3.00 to 20.00 mm (.118 to .787 in).Ejector Carrier Rollers
(631 & 637)
Adjust
1. The ejector should operate freely without dragging. To adjust the carrier rollers, loosen the clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller.3. Tighten the clamping bolt. Clearance between the bottom of the ejector and the bottom of the bowl should be 1.0 to 13.0 mm (.04 to .50 in).Ejector Support Rollers
(631 & 637)
Adjust
1. The ejector should operate freely without dragging. To adjust the carrier rollers, loosen the clamping bolt. 2. Turn the roller (eccentric) shaft to position the roller. 3. Tighten the clamping bolt. The distance between rollers, outside to outside, should be .00 to 6.00 mm (.00 to .236 in) less than the narrowest dimension between the roller guide tracks.Refer to the Service Manual for your machine or contact your Caterpillar dealer for the correct adjustment procedure.Ejector Carriage Rollers
(639)
Adjust
Do not get under the push frame unless the front engine is stopped and the ejector floor is blocked.
1. Install pin in the position that will block movement of the carriage.See "Blocking the Ejector Floor Closed" in the "Safety" section of the Operation (Operator's) Guide. 2. The carriage should operate freely without binding. To adjust the carriage rollers, loosen the roller shaft clamping bolt. 3. Turn the roller (eccentric) shaft to position the rollers. 4. Tighten the clamping bolt. The distance between rollers, outside to outside, should be .00 to 1.50 mm (.00 to .060 in) less than the narrowest dimension between the guide tracks on the push frame.