101602-9811 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016029811 3436100040

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-9811 1016029811

MITSUBISHI-HEAV 3436100040 3436100040

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Service parts 101602-9811 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8120

3. GOVERNOR 105410-9501

4. SUPPLY PUMP 105220-5581

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4620

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 21.6(220)

13. NOZZLE-HOLDER 105048-3330

14. NOZZLE

105017-0530

15. NOZZLE SET

Include in #1:

101602-9811 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-1810 as _

Cross reference number

ZEXEL 101602-9811 1016029811

MITSUBISHI-HEAV 3436100040 3436100040

Zexel num

Bosch num

Firm num

Name

101602-9811
101602-9812

3436100040 MITSUBISHI-HEAV

INJECTION-PUMP ASSEMBLY
S6K-T * 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 131424-5720

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 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive 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 A

Rack position 7.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 50.5 49.5 51.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.8+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 12 10.7 13.3

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 D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 57.6 57.6 62.6

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)The torque control spring does not operate. (4)RACK LIMIT (5)Main spring setting (6)Set idle sub-spring
----------
K=12
----------

Speed control lever angle

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

----------
a=19deg+-5deg b=2deg+-5deg

Stop lever angle

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

----------
a=26.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

1. Remove bolts (1) and the washers that hold rocker shaft assembly (2) in position.2. Remove rocker shaft assembly (2). Remove the O-ring seal from the rear rocker arm support bracket.3. Put identification marks on push rods (3) as to their location in the engine. Remove the push rods.Install Rocker Shaft Assembly & Push Rods
1. Install push rods (1). Make sure they are in their original location in the engine and in position in the valve lifters.
Loosen the adjusting screws on the rocker arms. This will prevent a bent valve or push rod during installation of the rocker shaft assembly.
2. Install a new O-ring seal in the rear rocker arm support bracket. Put 2P2506 Thread Lubricant on all of the bolts that hold the rocker shaft assembly in position except for the bolt that goes through the rear rocker arm support bracket.3. Put rocker shaft assembly (2) in position on the engine. Make sure the dowels in the support bracket are in alignment with the dowel holes in the cylinder head. Make sure the rocker arms are engaged with the push rods.4. Install the bolts and washers that hold the rocker shaft assembly in position. Tighten them until they are finger tight.
3304 Engine Sequence
3306 Engine Sequence5. Tighten the bolts that hold the rocker shaft as follows:a. Tighten the bolts in number sequence to a torque of 156 N m (115 lb ft).b. Tighten the bolts in number sequence to a torque of 250 17 N m (185 13 lb ft).c. Tighten the bolts again in number sequence to a torque of 250 17 N m (185 13 lb ft).6. See "Valve Clearance Setting" in Testing & Adjusting. Make an adjustment to the valves so the intake valves have 0.38 mm (.015 in) clearance and the exhaust valves have 0.64 mm (.025 in) clearance. Tighten the locknuts for the adjusting screws to a torque of 29 7 N m (21 5 lb ft).End By:a. install valve cover