Information injection-pump assembly
BOSCH
F 01G 09U 04M
f01g09u04m
ZEXEL
101606-6730
1016066730
MITSUBISHI
ME076547
me076547
Rating:
Service parts 101606-6730 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076565
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
101606-6730
as INJECTION-PUMP ASSEMBLY
Include in #2:
104701-1031
as _
Cross reference number
BOSCH
F 01G 09U 04M
f01g09u04m
ZEXEL
101606-6730
1016066730
MITSUBISHI
ME076547
me076547
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
131424-5520
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
RED3 control unit part number
407910-2
470
RED3 rack sensor specifications
mm
15
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
4.2
4.15
4.25
Beginning of injection position
Governor side NO.1
Governor 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
Rack position
(11.4)
Vist
V
1.72
1.72
1.72
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
88
87
89
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Injection quantity adjustment_02
Rack position
(7.9)
Vist
V
2.4
2.3
2.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
10.5
9
12
Max. variation between cylinders
%
0
-10
10
Test data Ex:
Governor adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C3=(8)deg t1=2--sec. t2=2--sec.
----------
N1=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=0.5--deg C2=8+-0.3deg R01=0/4load R02=4/4load
----------
L=1.5+-0.2mm N2=800r/min C3=(8)deg t1=2--sec. t2=2--sec.
----------
N1=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=0.5--deg C2=8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=1mm bb=16mm
----------
a=31deg+-5deg b=29deg+-5deg
----------
aa=1mm bb=16mm
----------
a=31deg+-5deg b=29deg+-5deg
0000000901
(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=11deg
----------
a=(1deg)
----------
aa=11deg
----------
a=(1deg)
Stop lever angle
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 15 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
----------
----------
----------
----------
Information:
Turn the engine to (TDC) top center compression stroke for the No. 1 piston and install crankshaft flywheel timing pin. This will help when timing the camshaft when installing.
Wire used to hold cam roller followers up off camshaft. It is not necessary to remove the cylinder head. With the cylinder head in place, just wire the cam roller followers up off the camshaft and then remove the camshaft. 1. Remove camshaft retainer bolt (1) and remove camshaft assembly (2). The following steps are for the installation of the camshaft assembly. When installing the camshaft, rotating it both clockwise and counter clockwise directions will help prevent it from binding in the bearing bores.2. Put engine oil on the lobes and journals of the camshaft. Carefully install the camshaft. When installing the camshaft, be sure the number one cylinder is at (TDC) top dead center of the compression stroke with the timing pin installed in the flywheel. Camshaft timing is very important. Cam gear timing marks must line up with idler gear timing marks as illustrated. For more information about timing of engine, refer to SPECIFICATIONS module, FORM No. SENR3908.
Camshaft Timing3. With the camshaft properly timed and positioned, install retaining bolt (1). Tighten bolt (1) to a torque of 48 7 N m (35 5 lb.ft.). Remove the wire that was used to hold the cam roller followers up off the camshaftEnd By:a. install fuel transfer pumpb. install front coverc. install front pulley and damperd. install fuel injectorse. install rocker arm assemblies and push rodsDisassembly And Assembly of Camshaft And Gear/Weight Assembly
If the disassembly is being done, just to replace any or all of the twelve retainers, then it may not be necessary to remove the weight assembly from the camshaft. Depending on the press set-up, the retainers may be removed and installed with the camshaft and weight assembly still assembled.Start By:a. remove camshaft assembly 1. Wrap camshaft portion of camshaft and gear/weight assembly (1) with paper towels (2) to protect the camshaft from being damaged. Remove bolts (3) and remove cover plate (4) from assembly (1). Care must be taken not to damage the timing/speed sensor ring gear when removing. Using the prybar, work around the ring gear and pry the ring gear off a little at a time. 2. Using a prybar, carefully pry timing/speed sensor ring gear (5) off the gear/weight assembly. 3. Reposition the camshaft and gear/weight assembly. Remove bolts (6) and remove retainer ring (7), then remove cam gear (8).
Care must be taken not to allow the camshaft to fall to the floor when pressing it from the weight. Also be sure that a camshaft lobe does not catch on the press plates.
4. Place the camshaft and weight assembly through spacer pipe (10) and place it in the press as illustrated. Press the camshaft from weight assembly (9). 5. Position weight assembly (9) in press as illustrated. Use a small spacer pipe (11) to support weight (9) and with a block on
Wire used to hold cam roller followers up off camshaft. It is not necessary to remove the cylinder head. With the cylinder head in place, just wire the cam roller followers up off the camshaft and then remove the camshaft. 1. Remove camshaft retainer bolt (1) and remove camshaft assembly (2). The following steps are for the installation of the camshaft assembly. When installing the camshaft, rotating it both clockwise and counter clockwise directions will help prevent it from binding in the bearing bores.2. Put engine oil on the lobes and journals of the camshaft. Carefully install the camshaft. When installing the camshaft, be sure the number one cylinder is at (TDC) top dead center of the compression stroke with the timing pin installed in the flywheel. Camshaft timing is very important. Cam gear timing marks must line up with idler gear timing marks as illustrated. For more information about timing of engine, refer to SPECIFICATIONS module, FORM No. SENR3908.
Camshaft Timing3. With the camshaft properly timed and positioned, install retaining bolt (1). Tighten bolt (1) to a torque of 48 7 N m (35 5 lb.ft.). Remove the wire that was used to hold the cam roller followers up off the camshaftEnd By:a. install fuel transfer pumpb. install front coverc. install front pulley and damperd. install fuel injectorse. install rocker arm assemblies and push rodsDisassembly And Assembly of Camshaft And Gear/Weight Assembly
If the disassembly is being done, just to replace any or all of the twelve retainers, then it may not be necessary to remove the weight assembly from the camshaft. Depending on the press set-up, the retainers may be removed and installed with the camshaft and weight assembly still assembled.Start By:a. remove camshaft assembly 1. Wrap camshaft portion of camshaft and gear/weight assembly (1) with paper towels (2) to protect the camshaft from being damaged. Remove bolts (3) and remove cover plate (4) from assembly (1). Care must be taken not to damage the timing/speed sensor ring gear when removing. Using the prybar, work around the ring gear and pry the ring gear off a little at a time. 2. Using a prybar, carefully pry timing/speed sensor ring gear (5) off the gear/weight assembly. 3. Reposition the camshaft and gear/weight assembly. Remove bolts (6) and remove retainer ring (7), then remove cam gear (8).
Care must be taken not to allow the camshaft to fall to the floor when pressing it from the weight. Also be sure that a camshaft lobe does not catch on the press plates.
4. Place the camshaft and weight assembly through spacer pipe (10) and place it in the press as illustrated. Press the camshaft from weight assembly (9). 5. Position weight assembly (9) in press as illustrated. Use a small spacer pipe (11) to support weight (9) and with a block on