101603-6270 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016036270 me035574

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-6270 1016036270

MITSUBISHI ME035574 me035574

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Cross reference number

ZEXEL 101603-6270 1016036270

MITSUBISHI ME035574 me035574

Zexel num

Bosch num

Firm num

Name

101603-6270

ME035574 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D14 * 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 131424-3720

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Governor 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 -

Rack position 11.5

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 61.5 59.7 63.3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 9.7+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 10.5 9 12

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.5)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 61.5 60.5 62.5

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(11.5)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 65.8 63.1 68.5

Difference in delivery mm3/st. 5.4 5.4 5.4

Fixing the lever *

Timer adjustment

Pump speed r/min 850+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 2.6 2.1 3.1

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Excess fuel setting for starting: SXL
----------
DL=6.5-0.2mm SXL=R1(11.5)+1+0.8mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=13deg+-5deg

0000000901

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

----------
a=27.5deg+-3deg b=57deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=2.5mm bb=21mm
----------
a=71deg+-5deg b=20deg+-5deg c=(9.5deg)

Timing setting

(1)Pump vertical direction (2)Position of gear mark '2' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=16deg
----------
a=(90deg)

Information:

Table 2
Specifications for Valve Opening Pressure
Nozzle Assembly Valve Opening Pressure
1W-5829
10300 to 17690 kPa (1500 to 2505 psi)
4W-1819
4W-8483
7E-3969
7N-0449
7W-3710
7W-8043
9N-3979
101-0060
115-3354
122-9007
9L-7883
16560 to 17990 kPa (2400 to 2600 psi)
9L-9263
9N-2366
9L-6969
13090 to 19900 kPa (1900 2900 psi)
9N-3299
9N-3700 If the fuel nozzle is not within specifications, stop the test and do not use the nozzle.Check for Tip Leakage
Close the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge).
Flush the fuel nozzle that is being tested by pumping the tester for 3 full strokes.
Open the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge).
Use a clean cloth to dry the tip and the body of the fuel injector. All test fluid should be wiped from the nozzle assembly.
A clean cloth should be wrapped around the top of the fuel nozzle in order to absorb any internal return leakage.
Calculate the test pressure that will be used for the tip leakage test.Use the fuel nozzle's valve opening pressure, that has been previously recorded, in order to calculate the test pressure for the nozzle that is being tested.
Subtract a value of 1875 kPa (275 psi) from the valve opening pressure that was previously obtained.
Record the result of the calculation as the test pressure that will be used for the tip leakage test.
Slowly apply the test pressure, that has been calculated in Step 6, to the fuel nozzle.
Close the pump isolator valve.
Hold this test pressure for 10 seconds.
Count the number of drops of test fluid that drips from the nozzle during the duration of the test. Open the pump isolator valve in order to release the pressure on the fuel nozzle when the test is completed.Refer to the information that is provided in Table 3 in order to evaluate the results of the test.Note: Ensure that any test fluid that collects on the tip of the fuel nozzle is not fluid leakage from the test fixture.
Table 3
Specifications for Tip Leakage
(Leakage within 15 seconds after the test pressure is applied to the nozzle.)
Nozzle Assembly Maximum Leakage
1W-5829 20 drops (1)
4W-1819
4W-8483
7E-3969
7N-0449
7W-3710
7W-8043
9N-3979
101-0060
115-3354
122-9007
9L-7883 3 drops (1)
9L-9263
9N-2366
9L-6969 30 drops (1)
9N-3299
9N-3700
( 1 ) No minimum specificationIf the tip leakage for the fuel nozzle is not within specifications, stop the test and do not use the fuel nozzle.Test the Fuel Nozzle for Plugged Orifices
Illustration 2 g00923165
Spray patterns for pencil type fuel nozzles.
Close the gauge protector valve (0 to 40,000 kPa (0 to 5,800 psi) gauge).
Rapidly increase the pressure on the fuel nozzle until fluid sprays from the tip of the fuel nozzle.Note: For this test, each full