Information injection-pump assembly
ZEXEL
101602-9990
1016029990
MITSUBISHI-HEAV
3436109010
3436109010
Rating:
Cross reference number
ZEXEL
101602-9990
1016029990
MITSUBISHI-HEAV
3436109010
3436109010
Zexel num
Bosch num
Firm num
Name
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
131424-5720
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
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.
53
52
54
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.4+-0.5
Pump speed
r/min
400
400
400
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.
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.
58
58
63
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)The torque control spring does not operate.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
----------
K=12
----------
----------
K=12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=4deg+-5deg b=19deg+-5deg
----------
----------
a=4deg+-5deg b=19deg+-5deg
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 camshaft's key groove at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
If fuel line clamps are not installed in their exact location, vibration can cause the fuel lines to break and cause possible personal injury, or damage to the machine.
1. Disconnect front fuel injection lines (1), disconnect middle fuel injection lines (2) and rear fuel injection lines (3) from the fuel injection pump and the cylinder head assembly.2. Remove fuel injection lines (1), (2) and (3). Put caps or plugs on all fuel line connections to keep foreign material out of the fuel system.3. If a separation of the fuel lines has to be made, make sure the exact location of the clamps are marked for assembly purposes. Remove the clamps and make a separation of the fuel lines. The following steps are for the installation of the fuel injection lines.4. Remove the caps or plugs for the fuel injection line connections.5. If removed, connect the fuel lines with the clamps. Make sure the clamps are installed back in their correct location. Use Tool (A) to tighten the clamp bolts to a torque of 2.3 N m (20 lb in). For more information, see Specifications Manual SENR6470, of Testing & Adjusting Manual SENR6471.6. Install front fuel injection lines (1) on the fuel injection pump and cylinder head assembly.7 Install middle fuel injection lines (2) on the fuel injection pump and the cylinder head assembly.8. Install rear fuel injection lines (3) on the fuel injection pump and the cylinder head assembly.9. Tighten the fuel injection line nuts to a torque of 40 7 N m (30 5 lb ft).