101492-1030 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014921030


 

Information injection-pump assembly

ZEXEL 101492-1030 1014921030
101492-1030 INJECTION-PUMP ASSEMBLY
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Cross reference number

ZEXEL 101492-1030 1014921030


Zexel num
Bosch num
Firm num
Name
101492-1030 
101492-1031 
 
  MITSUBISHI
INJECTION-PUMP ASSEMBLY
4D31T *

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   *

Test data Ex:

Governor adjustment

Test data 101492-1030
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

Test data 101492-1030
F:Full speed I:Idle (1)Set the pump speed at aa (2)At shipping (3)Set the pump speed at bb. (4)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=22deg+-5deg b=1deg+-5deg c=(2deg) d=6deg+-5deg

Stop lever angle

Test data 101492-1030
N:Pump normal S:Stop the pump.
----------

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

Timing setting

Test data 101492-1030
(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:

1. Remove turbocharger return oil line (1).2. Remove two shields (2) from exhaust manifold (3). 3. Remove clamp (4).4. Remove nuts, spacers and brackets (5).5. Remove exhaust manifold (3).6. Remove the gaskets from the exhaust manifold or studs. 7. Separate section (6), sections (7) and section (8).Install Exhaust Manifold
Make sure the 2P-2333 Manifold Sealer does not get on the inside of each manifold. Damage to the turbocharger could be the result if the manifold sealer gets on the impeller on the turbocharger.
1. Apply a thin coat of 2P-2333 Manifold Sealer to the O.D. of male end of the manifold sections (7) and section (8). Coat the female ends of the manifold with clean engine oil.2. Connect sections (6), sections (7) and section (8). 3. Install 5P-3931 Anti-Seize Compound on the threads of studs (9).4. Install the gaskets on the studs. 5. Install exhaust manifold (3).6. Install nuts, spacers and brackets (5). Tighten the nuts to a torque of 38 5 N m (28 4 lb ft).7. Install clamp (4). 8. Install two shields (2) to exhaust manifold (3).9. Using a new O-ring seal at the bottom and a new gasket at the top, install turbocharger return oil line (1).

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