Information injection-pump assembly
ZEXEL
101607-6940
1016076940
Rating:
Service parts 101607-6940 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076787
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
ZEXEL
101607-6940
1016076940
Zexel num
Bosch num
Firm num
Name
101607-6940
INJECTION-PUMP ASSEMBLY
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
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
Adjusting point
-
Rack position
13
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
96.8
93.9
99.7
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.
10.2
8.7
11.7
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
96.8
95.8
97.8
Basic
*
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.35
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
100.3
96.3
104.3
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2-0.6
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
66.9
62.9
70.9
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2(R1+0.
25)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
96.5
92.5
100.5
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
95
75
115
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
450
450
450
Rack position
R2-0.6
Boost pressure
kPa
6
4.7
7.3
Boost pressure
mmHg
45
35
55
Boost compensator adjustment_02
Pump speed
r/min
450
450
450
Rack position
R2(R1+0.
25)
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Timer adjustment
Pump speed
r/min
1200--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1150
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1350
Advance angle
deg.
2.5
2
3
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Boost compensator stroke: BCL
----------
T1=D24 BCL=0.6+-0.1mm
----------
----------
T1=D24 BCL=0.6+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=41deg+-3deg
----------
aa=35mm
----------
a=33deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection.
(3)After setting the stopper bolt, confirm non-injection at speed dd. Rack position = ee (non-injection rack position)
----------
aa=50mm bb=1400r/min cc=6.5-0.5mm dd=275r/min ee=(8.6)-0.5mm
----------
a=25deg+-5deg b=27deg+-5deg
----------
aa=50mm bb=1400r/min cc=6.5-0.5mm dd=275r/min ee=(8.6)-0.5mm
----------
a=25deg+-5deg b=27deg+-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=400r/min Ra=9.2+-0.1mm
----------
----------
N1=400r/min Ra=9.2+-0.1mm
----------
0000001601 TAMPER PROOF
1. Method for setting tamperproof proofing
(1)Perform after governor adjustment (torque cam phase adjustment).
(2)Increase the full rack position to aa using the load lever.
(3)At N = N1, push in screw (A) until Ra.
(4)Temporarily caulk using the tip of a screwdriver
(5)Confirm that the rack at that time is Rb.
(6)Lock using setscrew (B). (Tightening torque = T)
(7)Pressfit (C) after applying adhesive.
(8)Readjust the full rack using the load lever.
----------
aa=(0.4)mm N1=1400r/min Ra=(R1+0.1)+-0.1mm Rb=(R1+0.1)+-0.1mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)
----------
aa=(0.4)mm N1=1400r/min Ra=(R1+0.1)+-0.1mm Rb=(R1+0.1)+-0.1mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)
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)
----------
aa=12deg
----------
a=(1deg)
Information:
Illustration 13 g02915447
Plugged DOC
The DOC utilizes a “pass-through” technology, which is different from the “wall flow” design of a DPF. When a light is shined through the DOC, a visible light should be able to pass through. Utilize a flashlight to check for a plugged DOC face. Aim the flashlight into the DOC inlet, visible light should be seen through the DOC. A plugged DOC can be caused by high oil consumption, not recommended fuel additives, or wrong engine oil types. Refer to the Operation and Maintenance Manual for recommended fluids to use. If light cannot be seen on the outlet of the DOC, then replace the DOC.CRS Bodies
Illustration 14 g06342815
Combustion Group
(1) Head Group - Combustion
(2) Gasket
(3) Tube
(4) Body Assembly - Exhaust CombustionCRS Combustion Body (4) contains the flame necessary for CRS Regeneration. There are two combustion stages that occur within the CRS Body: the primary and secondary combustion. The primary combustion of air and fuel occur within Tube (3) to create the CRS flame immediately following Head Group (1). The secondary combustion of the CRS flame and exhaust gas from the turbocharger occur within Body Assembly (4).The body assembly is the only salvageable part of the combustion group. The body assembly must be cleaned, inspected, and pressure tested prior to reuse.Cleaning
Start by isolating the CRS body from all other CRS exhaust components. Remove the head group, the mounting studs, the tube, and the two gaskets.The gasket area and the bellows joints are the two areas of the CRS body that must be cleaned thoroughly to make a proper seal.Cleaning the remainder of the CRS body is not required. If cleaning the CRS body is desired, then first perform the visual inspection, vacuum inspection, and welding procedures prior to washing the CRS body. This step is to ensure that the CRS body is salvageable, not cracked, and to keep water from getting trapped behind the heat shield.If washing is preferred, then use soap and water as a cleaning solution. Do not submerge the CRS body to prevent water from becoming trapped between the heat shield and the CRS body. A cylinder washing brush, a wire brush with handle, and a greenScotch Brite pads are all acceptable cleaning equipment. Removal of all diesel particulates is not required for inspection.
Do not use any combustible solvents to clean the CRS body.
Visual Inspection
A visual inspection of the CRS body must be completed, special equipment or crack detecting solution is not required. Visually inspect the exterior of the CRS body. Small cracks and/or punctures found on the stainless steel heat shield is normal and should be expected. Inspect the bellows sealing joints and the CRS head mating surface for visual damage.Light surface rust is typically not a problem unless rust is found on a bellows joint or the CRS gasket mating surface. Light rust in these two areas must be removed using a Scotch Brite pad.Serviceability
All bolts, studs, and clamps are not reusable and must be replaced with new components.Any thread damage in the mounting
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Mitsubishi
101607-6940
INJECTION-PUMP ASSEMBLY