Information injection-pump assembly
ZEXEL
101607-6941
1016076941
Rating:
Service parts 101607-6941 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
101607-6941
1016076941
Zexel num
Bosch num
Firm num
Name
101607-6941
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=(39deg)+-3deg
----------
aa=35mm
----------
a=33deg+-5deg b=(39deg)+-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 1 g01491433
Measuring the outer diameter of the center section of the DPF
Illustration 2 g01756814
DPF flange designs (B) Standard flange (C) Submerged flange
Measure the outer diameter of the center section of the DPF. Illustration 1 shows the outer diameter of the center section of the DPF. Use Table 2 to locate the appropriate cone and the proper adapters for your application.Note: These adapters are part of the 319-2189 Diesel Particulate Filter Cleaner Gp .
Table 2
Model and Description for the DPF Outer Diameter of the Center Section of the DPF
"A" Large Cone
319-1836 Medium Cone
319-1835 Small Cone
319-2192 Upper Adapter for Mass Transit Buses (MTB)
319-2192 Lower Adapter
319-1838 Lower Adapter
319-1839 Gasket Part Number
(mm) (inches)
9.5 x 14 Submerged 253.1 10 X X 293-6156
9.5 x 14 Standard 279.3 11 X X 279-3259
11.25 x 14 Submerged 279.3 11 X X 279-3259
264-1556 Filter Module As MTB 318.2 12.5 X X X 247-1899
11.25 x 14
MTB Standard 321.1 12.6 X X 279-1081
13 x 15 or 13 x 17 Submerged 342.8 13.5 X X 279-2123
12 x 15 342.8 13.5 X X 279-2123
13 x 15 or 13 x 17Standard 368.2 14.5 X X 278-5711 Note: All the pressure ports and the thermocouple ports on the DPF must be plugged before cleaning.
Illustration 3 g01491993
Plug any other open ports on the DPF.
Install a 2F-2990 Seal Plug or a 102-9379 Plug in all the open ports on the DPF.
Assemble the DPF. Refer to the engine Disassembly and Assembly Manual, "Diesel Particulate Filter - Assemble" for the proper procedure to assemble the DPF.
Reinstall the DPF onto the vehicle.Ash Service Reset
The engine ash model must be reset whenever the filter is cleaned or replaced. This resets the DPF volume back to the "Clean State". The resetting will allow the regeneration of the DPF to function properly.
Use Cat ET to access the configuration parameters. In the "System Settings" group of parameters, highlight the" Diesel Particulate Filter Ash Service Reset". Refer to Illustration 4 for the location of the " Diesel Particulate Filter Ash Service Reset". The value of the parameter should be "Not Reset".
Click the "Change" button at the bottom of the screen. The change will require the Factory Passwords to be reset. Enter "Reason code 67".
Enter the
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Mitsubishi
101607-6941
INJECTION-PUMP ASSEMBLY