101603-6510 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016036510 me056529

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-6510 1016036510

MITSUBISHI ME056529 me056529

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Cross reference number

ZEXEL 101603-6510 1016036510

MITSUBISHI ME056529 me056529

Zexel num

Bosch num

Firm num

Name

101603-6510
101606-1450

ME056529 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D22 * 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 131424-5120

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 4.5 4.45 4.55

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 9.6

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 112 108.6 115.4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 18.5 15.7 21.3

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 112 111 113

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.6)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 113.5 111 116

Difference in delivery mm3/st. 9 9 9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 170 150 190

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 800+120- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 800

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 0.9 0.4 1.4

Timer adjustment_04

Pump speed r/min 1250

Advance angle deg. 4 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Adjust with the load control lever in the full position (variable speed specification). (3)Damper spring setting: DL (4)Excess fuel setting for starting: SXL (5)When air cylinder is operating.
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DL=7.5-0.2mm SXL=11.6+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Pump speed = bb (3)Pump speed cc (4)Air cylinder's adjustable range
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aa=1150r/min bb=300r/min cc=575r/min
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a=10deg+-5deg b=4deg+-5deg c=15deg+-5deg d=10deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=21deg+-5deg b=23.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=2.5mm bb=21mm
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a=71deg+-5deg b=12deg+-5deg c=(9.5deg)

0000001501 2-STAGE CHANGEOVER DEVICE

RFD governor 2 stage changeover mechanism adjustment outline (A) Bolt (B) bolt (c) Nut (D) Return spring (E) Bolt (F) Bolt (G) Screw (H) Bolt (I) Load lever (J) Speed lever (K) Air cylinder (M Air inlet Figure 1 is only for reference. Lever shape, etc, may vary. 1. Minimum-maximum speed specification adjustment (when running) (a) Without applying air to the air cylinder, loosen bolts (A) and (B). (1)High speed return L setting (a) In the speed range Nf~Nf - 300r/min, adjust using the speed adjusting bolt to determine the temporary beginning of high speed control speed. (b) Determine the rack position in the vicinity of Rf using the full load lever. (c) Increase speed and confirm return distance L. (d) Adjust using the tension lever bolt to obtain L. (2)Setting full load rack position Rf (a) Move the load control lever to the full side. (b) Adjust the full load adjusting bolt so that Rf can be obtained, then fix. (3)Setting the beginning of high speed operation Nf (a) Adjust using bolt (E) so that Nf can be obtained, and then fix. (4)Idle control setting (Re, Ni, Rc) (a) Set the speed at Ns + 200r/min and move the load control lever to the idle side. (b) Fix the lever in the position where Re can be obtained. (c) Next, decrease speed to Ni and screw in the idle spring. (d) Adjust to obtain rack position Ri. (e) Increase the speed and after confirming that the rack position is Re at Ns, set the speed at 0. (f) Confirm protrusion position Rc at idle. (5)Damper spring adjustment (a) Increase speed and set the speed at the rack position Rd - 0.1 mm (b) Set using the damper spring so that the rack position Rd can be obtained. (c) When Rd is not specified, Rd = Ri - 0.5 mm. (6)High speed droop confirmation (a) Return the load control lever to the full load lever position. (b) Increase the speed and confirm that Rf can be obtained at Nf r/min. (c) Confirm that speed is Nh at rack position Rh. 2. Variable speed specification adjustment (at operation) (a) Remove return spring (D). (b) Apply air pressure of 245~294 kPa {2.5~3 kg/cm2} to the air cylinder. (c) Perform the following adjustment in this condition. (1)Setting full load rack position Rf' (a) Pull the load lever to the idle side. (b) Obtain rack position Rf' using the nut (C). (Pump speed is Nf'-50 r/min.) (2)Setting full speed Nf' (a) Adjust using bolt (B) so that Nf can be obtained, and then fix. (3)Low speed side setting (a) At 350r/min, set bolt (F) at beginning of governor operation position, then fix. 3. Bolt (A) adjustment (1)Install return spring (D) and perform the adjustments below at air pressure 0. (a) Set at speed Nf using bolt (E). (b) Screw in bolt (A). (c) Screw in 1 more turn from the speed lever contact position (d) Fix bolt (A). (e) At this time confirm that the air cylinder's shaft moves approximately 1 mm towards the governor. 4. Lever operation confirmation using the air cylinder (1)Apply 588 kPa {6 kg/cm2} air pressure to the air cylinder. (2)Confirm that the cylinder piston is moved 50 mm by the spring (D).
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0000001601 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
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N1=325+-5r/min Ra=7.3mm
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Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
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a=(7deg)

Information:

Introduction
The following procedures contain crucial information on correctly installing the new 162-2501 Hose As and the 258-8917 Protection Sleeve .Note: The 162-2501 Hose As replaces 107-7942 Tube As .Installation Procedure of the Hose Assembly
Illustration 1 g01230674
Remove old 162-2501 Hose As (1). Keep all of the manifold and pump fittings attached.Note: Step 2 is only for 3408E engines.
Remove the 7W-6492 Pipe Plug (2) from the aftercooler housing (3). Install the 8T-6762 Pipe Plug into the aftercooler housing.
Illustration 2 g01230678
Note: Always tighten the fittings with your hand before you use a wrench. Support the hose and the elbow while you tighten in order to avoid the following damage: twisting, kinking and side loading.
Loosen elbow (4) and jam nut (5) .
Hand tighten the nut on the hose (5) to the elbow (4) .
Install the other end of the hose (6) to the pump fitting. Tighten the nut to 125 15 N m (90 11 lb ft).
Hold the elbow (4) in position and torque the jam nut to 145 15 N m (105 11 lb ft).
Support the elbow (4). Tighten the nut (5) on the hose to 125 15 N m (90 11 lb ft).
Illustration 3 g01230687
Illustration 3 shows the routing of the 162-2501 Hose As (8). The hose is routed from the rail, around the rear of the fuel transfer pump (9), and into the 90 degree fitting (7) that is installed into the pump.
Illustration 4 g01230689
Some 3408 engines use an aftercooler that is mounted high. The mounting bracket (10) is located close to the 162-2501 Hose As (8). If there is not enough clearance to install the protective sleeve, the hose will need to be loosened and the hose will need to be repositioned. Refer to 5 for repositioning of the hose.
Illustration 5 g01230690
The hose must be realigned if any of the following conditions exist:
Not enough clearance against the fuel transfer pump
Not enough clearance against the support bracket
Loosen the end of the hose (12) .
Loosen the elbow and the jam nut (11). Note: Do not remove the hose.
Reposition the hose in order to acquire the desired clearance.
Hold the end of the hose (12). Tighten the jam nut (11) .Tighten the jam nut to the following torque. ... 143 15 N m (105 11 lb ft)Note: Locking pliers can be used on the crimped portion of the hose. Do not use the locking pliers on the braided portion of the hose. This will damage the hose which will cause a failure.
Tighten the end of the hose (12) .Tighten the end of the hose to the following torque. ... 125 15 N m (92 11 lb ft)Note: If adjustment of the hose is required, make sure that the hose is not bent. Also, ensure that the hose is not twisted. If these conditions exist the PTFE liner can be damaged.Installation of the Protective Sleeve Over the New Hose Assembly
Illustration 6 g01106118
Top viewInstallation of a protective sleeve for the hoses of the