101606-1121 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016061121

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101606-1121 1016061121

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Cross reference number

ZEXEL 101606-1121 1016061121

Zexel num

Bosch num

Firm num

Name

101606-1121
101606-1122

MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D15 *

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 131424-5520

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 3.6 3.55 3.65

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 10.8

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 60 58.1 61.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 9.3 8.2 10.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.8)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 60 59 61

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.6

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 80.5 78.5 82.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 75 85

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1350

Advance angle deg. 2.4 1.9 2.9

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C70
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=10deg+-5deg b=(46deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee. (4)Free (at shipping)
----------
aa=1550r/min bb=(7.1)mm cc=275r/min dd=(8.8)mm ee=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg

0000001501 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
----------
N1=400+-5r/min Ra=9.2mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(1deg)

Information:

Illustration 4 g01621593
(4) The process of crimping has been improved in the location that is shown. The Fifth Improvement
The length of the bolts that secure the fuel transfer pump to the HEUI pump body have increased. The torques on the bolts that secure the transfer pump to the HEUI pump body have also increased in order to improve durability.
HEUI pumps that have been returned from the field have been inspected and broken bolts that connect the fuel transfer pump to the main HEUI pump were found.
The major symptom that is related to this issue is an oil leak between the fuel transfer pump and the HEUI pump.
The bolts that make this connection were lengthened as well as the torques were increased in order to provide a better connection.
This improvement was effective with the following part numbers: 319-0607, 319-0674, 319-0675, 319-0676, 319-0677, 319-0678, 319-0622, 319-0610 and 319-0680
Illustration 5 g01621594
(5) Location of the three bolts that have been lengthened and increased torques have been applied. Note: The applications that utilize an electric fuel transfer pump also have this improvement for the cover that goes in place of the mechanical fuel transfer pump.Note: Refer to Special Instruction , REHS3830 for the following items: parts information, installation of parts and torque procedures that are related to this improvement.All current remanufactured part numbers are being built with the latest improvements. A list of all the current new part numbers and the part numbers of the remanufactured equivalent can be seen below.
Table 1
Current New Part Numbers Remanufactured Equivalent
319-0607 -
319-0674 -
319-0675 10R7145
319-0676 10R7146
319-0677 10R7147
319-0678 10R7148
319-0622 -
319-0610 10R3044
319-0680 - Note: All part numbers that are referenced in this publication were current on 15 July 2008. Part numbers are subject to a change.
Table 2
New Part Numbers Serial Number Prefixes that Use the Part Numbers
319-0607 S/N:532, ; S/N:551, ; S/N:511, ; S/N:521, ; S/N:522, ; S/N:525, ; S/N:535, ; S/N:541, ; S/N:545, ; S/N:552, ; S/N:B3T, ; S/N:B9D, ; S/N:B9M, ; S/N:D9G
319-0674 S/N:C7D, ; S/N:C7P, ; S/N:C7Z, ; S/N:M7A
319-0675 S/N:HEP, ; S/N:BTM, ; S/N:CAP, ; S/N:CGZ, ; S/N:GAG, ; S/N:HAA, ; S/N:JAB, ; S/N:JCD, ; S/N:KDD, ; S/N:MCA, ; S/N:CYA, ; S/N:GKX, ; S/N:JNK, ; S/N:RBH, ; S/N:MKM, ; S/N:MSD, ; S/N:MSL, ; S/N:CEX, ; S/N:CEH, ; S/N:BCP, ; S/N:CLJ, ; S/N:AEM, ; S/N:AFM, ; S/N:BLE, ; S/N:BLT, ; S/N:BMK, ; S/N:BNL, ; S/N:BPM, ; S/N:BRJ, ; S/N:CAD, ; S/N:FDT, ; S/N:ACJ, ; S/N:ADE, ; S/N:BNC, ; S/N:BPP, ; S/N:BPZ, ; S/N:AAX, ; S/N:AGM, ; S/N:BMJ, ; S/N:BMY, ; S/N:BPS, ; S/N:BRZ, ; S/N:AEP, ; S/N:DAE, ; S/N:L5J, ; S/N:BRE
319-0676 S/N:101, ; S/N:102, ; S/N:103, ; S/N:104, ; S/N:125, ; S/N:202, ; S/N:301, ; S/N:302, ; S/N:AMZ, ; S/N:B1K, ; S/N:B2L, ; S/N:B3M, ; S/N:B4N, ; S/N:CAP, ; S/N:CBK, ; S/N:D3C, ; S/N:DKY
319-0677 S/N:ECH, ; S/N:AWN, ; S/N:CJX, ; S/N:JKR, ; S/N:JLS, ; S/N:JGK, ; S/N:BYE, ; S/N:T2D, ; S/N:DFP, ; S/N:SYM, ; S/N:JJG, ; S/N:LAB, ; S/N:EJC, ; S/N:KJR, ; S/N:PEH, ; S/N:CJM, ; S/N:GBR, ; S/N:KDG, ; S/N:KBE, ; S/N:DBH, ; S/N:SCR, ; S/N:GPB, ; S/N:PKE, ; S/N:C7K, ; S/N:C9M, ;