101492-1100 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014921100 me017997

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101492-1100 1014921100

MITSUBISHI ME017997 me017997

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Service parts 101492-1100 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9031

3. GOVERNOR 105402-2000

4. SUPPLY PUMP 105220-5180

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-5320

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:

101492-1100 as INJECTION-PUMP ASSEMBLY

103662-3260 as _

Cross reference number

ZEXEL 101492-1100 1014921100

MITSUBISHI ME017997 me017997

Zexel num

Bosch num

Firm num

Name

101492-1100

ME017997 MITSUBISHI

INJECTION-PUMP ASSEMBLY
4D31PT * 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 9.8

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.

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)Setting at shipping (5)Idle sub spring setting: L1. (6)Rack difference between N = N1 and N = N2
----------
K=7 L1=9.2+-0.1mm N1=975r/min N2=600r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)At shipping (2)Stopper bolt setting
----------

----------
a=18deg+-5deg b=5deg+-5deg c=(12deg)

Stop lever angle

N:Pump normal S:Stop the pump. (1)At shipping
----------

----------
a=38deg+-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:

Use tool (E) in order to cut off the part of rivet (1) that has been peened. Remove rivet (1) from fuel injection control linkage (4) .
Illustration 13 g00702186
The 180-7951 Bushing Assembly Kit (F) Rack Control Shaft (G) Governor Link (4) Fuel Injection Control Linkage (7) 180-7952 Lever Bushing (8) 8L-5832 Hex Nut (9) 9X-8907 Hexagon Button Screw
Use the 180-7951 Bushing Assembly Kit in order to modify the linkage. Insert 9X-8907 Hexagon Button Screw (9) from the 180-7951 Bushing Assembly Kit into fuel injection control linkage (4). Refer to Illustration 13.
Apply 169-5464 Quick Cure Primer apply on the threads of 9X-8907 Hexagon Button Screw (9) and 8L-5832 Hex Nut (8). Allow the primer to dry. The Quick Cure Primer counteracts the effects of the Volatile Corrosion Inhibitor (VCI) paper that was used to package the parts.
Assemble 180-7952 Lever Bushing (7) on 9X-8907 Hexagon Button Screw (9). Refer to Illustration 13.
Apply the 154-9731 Thread Lock Compound on the threads of 9X-8907 Hexagon Button Screw (9) and 8L-5832 Hex Nut (8) .
Illustration 14 g00655322
Place 8L-5832 Hex Nut (8) on 9X-8907 Hexagon Button Screw (9). Tighten 8L-5832 Hex Nut (8) until hex nut (8) is snug. Tighten 8L-5832 Hex Nut (8) for an additional 180 degrees.
Do not let metal chips or pieces of the rivet fall into the engine.
Illustration 15 g00655325
Clean the fuel injection control linkage and clean the surfaces of the cylinder head that are adjacent to the fuel injection control linkage with shop solvent. Remove the towels and remove all debris very carefully.
Install the 180-7956 Clamp Assembly Kit . Refer to the "Installation Of The 180-7956 Clamp Assembly Kit " section of this publication.Installation Of The 180-7956 Clamp Assembly Kit
Note: The 180-7956 Clamp Assembly Kit is used for the former control linkages only.Note: If the 180-7956 Clamp Assembly Kit is installed, refer to ""Modification of the 128-9640 Injector Synchronization Fixture "".The 180-7956 Clamp Assembly Kit may be installed on the fuel injection control linkage. The 180-7956 Clamp Assembly Kit will increase the strength of the joint.
Illustration 16 g00655326
Install 183-9390 Spacer (10) on fuel injection control linkage (4). Refer to Illustration 16.
Apply 169-5464 Quick Cure Primer to the threaded hole in the 180-7954 Clamp (11). Apply 169-5464 Quick Cure Primer to the threads of screw (13). Allow the primer to dry. The Quick Cure Primer counteracts the effects of the Volatile Corrosion Inhibitor (VCI) paper that was used to package the parts.
Apply 154-9731 Thread Lock Compound to the threaded hole in the 180-7954 Clamp (11). Apply 154-9731 Thread Lock Compound to the threads of screw (13) of clamp assembly. Loosely assemble 180-7954 Clamp (11) and 180-7987 Clamp (12) on fuel injection control linkage (4). Refer to Illustration 16. Be sure that the rivet head or bushing (14) is fully engaged into the counterbore of the