101603-6080 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016036080

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-6080 1016036080

Service parts 101603-6080 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9680

3. GOVERNOR 105931-2280

4. SUPPLY PUMP 105210-4641

5. AUTOM. ADVANCE MECHANIS 105643-0100

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5980

11. Nozzle and Holder ME035749

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE 105015-5660

15. NOZZLE SET

Include in #1:

101603-6080 as INJECTION-PUMP ASSEMBLY

Include in #2:

104749-6872 as _

Cross reference number

ZEXEL 101603-6080 1016036080

Zexel num

Bosch num

Firm num

Name

101603-6080
101603-6082

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 R(12.1)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 88 87 89

Basic *

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.2

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 92 90 94

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.7

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 68.5 66.5 70.5

Fixing the lever *

Boost pressure kPa 28.7 28.7 28.7

Boost pressure mmHg 215 215 215

Injection quantity adjustment_06

Adjusting point I

Rack position 13.9+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 70 110

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-1.1

Boost pressure kPa 19.3 19.3 19.3

Boost pressure mmHg 145 145 145

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1-0.7

Boost pressure kPa 28.7 27.4 30

Boost pressure mmHg 215 205 225

Boost compensator adjustment_03

Pump speed r/min 600 600 600

Rack position R1(12.1)

Boost pressure kPa 45.3 38.6 52

Boost pressure mmHg 340 290 390

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=A08 BCL=1.1+-0.05mm
----------

Speed control lever angle

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

----------
a=33deg+-5deg b=41deg+-3deeg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Free (at shipping) (2)Rack position = approximately aa. (3)Set the stopper bolt at speed = rated point and rack position = bb. Confirm non-injection. (4)After setting the stopper bolt, confirm non-injection at speed = cc and rack position = dd.
----------
aa=17.4mm bb=(6)mm cc=275r/min dd=(8.5)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-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=9.2mm
----------

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=16deg
----------
a=(1deg)