101603-6201 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016036201

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-6201 1016036201

Cross reference number

ZEXEL 101603-6201 1016036201

Zexel num

Bosch num

Firm num

Name

101603-6201
101603-6202

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 D

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 R1(12.1)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 88 87 89

Basic *

Fixing the lever *

Boost pressure kPa 61.3 61.3

Boost pressure mmHg 460 460

Injection quantity adjustment_04

Adjusting point C

Rack position (R1-0.8)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 67 65 69

Fixing the lever *

Boost pressure kPa 28 28 28

Boost pressure mmHg 210 210 210

Injection quantity adjustment_05

Adjusting point E

Rack position 13.9+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 50 130

Fixing the lever *

Remarks
After startup boost setting

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 (R1-0.8)

Boost pressure kPa 28 26.7 29.3

Boost pressure mmHg 210 200 220

Boost compensator adjustment_03

Pump speed r/min 600 600 600

Rack position R1(12.1+ -0.5)

Boost pressure kPa 48 41.3 54.7

Boost pressure mmHg 360 310 410

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)Damper spring setting: DL (2)Boost compensator stroke
----------
DL=8.4-0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=13deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=19.5deg+-3deg b=26deg+-5deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Free (at shipping) (2)Rack position = aa (3)Rack position bb
----------
aa=13.5mm bb=7.5-0.5mm
----------
a=(3.5deg) b=15.5deg+-5deg c=24deg+7deg-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)