101492-1021 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014921021 me019337

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101492-1021 1014921021

MITSUBISHI ME019337 me019337

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Service parts 101492-1021 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9031

3. GOVERNOR 105400-2840

4. SUPPLY PUMP 105220-5180

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-2720

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4050

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7(180)

13. NOZZLE-HOLDER 105048-3010

14. NOZZLE

105017-0040

15. NOZZLE SET

Include in #1:

101492-1021 as INJECTION-PUMP ASSEMBLY

103662-3050 as _

Cross reference number

ZEXEL 101492-1021 1014921021

MITSUBISHI ME019337 me019337

Zexel num

Bosch num

Firm num

Name

101492-1021

ME019337 MITSUBISHI

INJECTION-PUMP ASSEMBLY
4D31T * 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 131424-4620

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 9.7

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 43.2 42.2 44.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.2+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 7.5 6.2 8.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point C

Rack position 11.6+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60.5 60.5 65.5

Fixing the lever *

Rack limit *

Injection quantity adjustment_04

Adjusting point D

Rack position 7.6+-0.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Setting at shipping (4)Idle sub spring setting: L1.
----------
K=10 L1=6.7+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)Set speed at bb (setting at shipping). (3)Set the pump speed to cc. (4)Stopper bolt setting
----------
aa=750r/min bb=950r/min cc=900r/min
----------
a=22deg+-5deg b=1deg+-5deg c=(2deg) d=6deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=27deg+-5deg b=53deg+-5deg

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)-
----------
aa=16deg
----------
a=(130deg)

Information:

2. Remove three nuts and washers (1).3. Move Peec unit (2) out of the way. (If so equipped). 4. Remove elbows (5) and pipes (7).5. Remove fuel line brackets (4).6. Remove bolts (6). Remove cover (3). 7. Remove elbows (10). Remove adapters (8) and adapters (9) from the aftercooler core. Remove bolts (11). 8. Move aftercooler core (12) toward the front of the engine and use two people to remove the aftercooler core from the lower aftercooler housing. The weight of the aftercooler core is approximately 29 kg (65 lb). Remove the O-ring seals from the aftercooler core extensions.Install Aftercooler
1. Install O-ring seals (13) on the aftercooler core extensions. Put clean engine oil or glycerin on the seals.2. Use two people to put aftercooler core (12) into position in the lower aftercooler housing. The weight of the aftercooler core is approximately 29 kg (65 lb). 3. Install bolts (11). Put clean engine oil or glycerin on O-ring seal (14) and in bores (15) and (16). 4. Put clean engine oil or glycerin on O-ring seals (17) and adapters (8) and (9). Install adapters (8) and (9) in the aftercooler core. 5. Install elbows (10). 6. Put cover (3) into position on the engine. Install bolts (6).7. Install fuel injection line brackets (4). Tighten bolts (20) to a torque of 4.5 1.1 N m (40 10 lb in).8. Put clean engine oil or glycerin on pipes (7). Install pipes (7) and elbows (5).9. Fill the cooling system with coolant. See Operation & Maintenance Manual for the proper procedure and levels.