Information injection-pump assembly
ZEXEL
101492-1080
1014921080
MITSUBISHI
ME018041
me018041
Rating:
Service parts 101492-1080 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME019368
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}
15.
NOZZLE SET
Cross reference number
ZEXEL
101492-1080
1014921080
MITSUBISHI
ME018041
me018041
Zexel num
Bosch num
Firm num
Name
101492-1080
ME018041 MITSUBISHI
INJECTION-PUMP ASSEMBLY
4D31T * K
4D31T * K
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
131424-4620
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.8
Pump speed
r/min
975
975
975
Average injection quantity
mm3/st.
66.4
65.4
67.4
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
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.
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
*
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)Torque spring does not operate.
(4)Idle sub spring setting: L1.
(5)Setting at shipping
----------
K=13 L1=9.2+-0.1mm
----------
----------
K=13 L1=9.2+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)At shipping
(2)Stopper bolt setting
----------
----------
a=18deg+-5deg b=5deg+-5deg c=(12deg)
----------
----------
a=18deg+-5deg b=5deg+-5deg c=(12deg)
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=27deg+-5deg b=53deg+-5deg
----------
----------
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)
----------
aa=16deg
----------
a=(130deg)
Information:
Start By:a. remove oil pumpb. remove timing gear coverc. remove flywheel housingd. remove pistons For more detail about removal of main bearings, see the topic "Remove & Install Crankshaft Main Bearings" in this module. 1. Check each bearing cap (1) for its location on the engine. Each cap has an arrow which is toward the front of the block and a number which gives the location of that cap. Keep each bearing with the correct cap.2. Remove bearing caps No. 2 through No. 6. Remove thrust plates from No. 4 upper bearing.3. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft as shown. Remove No. 1 and No. 7 main bearing caps. Remove the crankshaft. Weight of the crankshaft is 181 kg (400 lb).
Be careful not to damage the crankshaft journals when the crankshaft is removed.
4. Remove crankshaft gear (2) with Tooling (A).5. Remove dowel and pin from crankshaft with Tooling (B).Install Crankshaft
1. Install pin (1) in the crankshaft end until it is extended from the surface a distance of 6.4 0.5 mm (.25 .02 in).2. Install dowel (2) until it is extended from the surface a distance of 4.1 0.5 mm (.16 .02 in). 3. Heat crankshaft gear (3) to a maximum temperature of 232°C (450°F). Install gear (3) on the crankshaft with groove (4) in alignment with dowel (2).4. Make sure the upper main bearings are clean. Put clean oil on the upper main bearings and journals of the crankshaft. 5. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and put it in position in the block.
Use care to prevent damage to the crankshaft journals. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear.
For more detail about installation of main bearings, see Remove And Install Crankshaft Main Bearings.6. Check the bearing clearances with Plastigage.7. Put clean engine oil on the bolts for caps No. 1 and No. 7. Install No. 1 and No. 7 caps with the bolts finger tight. Make sure the arrows on the caps are toward the front of the block. 8. Install thrust plates (5) for the No. 4 upper main bearing. Install the thrust plates with the side that has identification "BLOCK SIDE" toward the cylinder block.9. Put clean oil on the bolts for caps No. 2 through No. 6. Install caps No. 2 through No. 6 with the bolts finger tight. Make sure the arrows are toward the front of the block.
Do not use an impact wrench to tighten the bolts the additional 120 degrees.
10. Tighten the cap bolts as follows:a. Tighten the bolts on the tab end of the caps first to a torque of 260 14 N m (190
Be careful not to damage the crankshaft journals when the crankshaft is removed.
4. Remove crankshaft gear (2) with Tooling (A).5. Remove dowel and pin from crankshaft with Tooling (B).Install Crankshaft
1. Install pin (1) in the crankshaft end until it is extended from the surface a distance of 6.4 0.5 mm (.25 .02 in).2. Install dowel (2) until it is extended from the surface a distance of 4.1 0.5 mm (.16 .02 in). 3. Heat crankshaft gear (3) to a maximum temperature of 232°C (450°F). Install gear (3) on the crankshaft with groove (4) in alignment with dowel (2).4. Make sure the upper main bearings are clean. Put clean oil on the upper main bearings and journals of the crankshaft. 5. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and put it in position in the block.
Use care to prevent damage to the crankshaft journals. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear.
For more detail about installation of main bearings, see Remove And Install Crankshaft Main Bearings.6. Check the bearing clearances with Plastigage.7. Put clean engine oil on the bolts for caps No. 1 and No. 7. Install No. 1 and No. 7 caps with the bolts finger tight. Make sure the arrows on the caps are toward the front of the block. 8. Install thrust plates (5) for the No. 4 upper main bearing. Install the thrust plates with the side that has identification "BLOCK SIDE" toward the cylinder block.9. Put clean oil on the bolts for caps No. 2 through No. 6. Install caps No. 2 through No. 6 with the bolts finger tight. Make sure the arrows are toward the front of the block.
Do not use an impact wrench to tighten the bolts the additional 120 degrees.
10. Tighten the cap bolts as follows:a. Tighten the bolts on the tab end of the caps first to a torque of 260 14 N m (190
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Mitsubishi
101492-1080
ME018041
INJECTION-PUMP ASSEMBLY
4D31T
4D31T