Information injection-pump assembly
ZEXEL
101608-1260
1016081260
Rating:
Service parts 101608-1260 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME075788
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Include in #1:
101608-1260
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-5660
as _
Cross reference number
ZEXEL
101608-1260
1016081260
Zexel num
Bosch num
Firm num
Name
101608-1260
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
131424-8420
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
3.2
3.15
3.25
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
11.7
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
78
75.7
80.3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
10+-0.5
Pump speed
r/min
480
480
480
Each cylinder's injection qty
mm3/st.
21.8
18.5
25.1
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.7)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
78
77
79
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
(R1+0.25
)
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
82.5
78.5
86.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
52.5
48.5
56.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
115
115
135
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
1
0.5
1.5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1200
Advance angle
deg.
1
0.5
1.5
Timer adjustment_05
Pump speed
r/min
1450
Advance angle
deg.
7
6.5
7.5
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
----------
T1=K59
----------
----------
T1=K59
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=21deg+-5deg b=(34deg)+-3deg
----------
aa=40mm
----------
a=21deg+-5deg b=(34deg)+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection.
(2)After setting the stopper bolt, confirm non-injection at speed = cc and rack position = dd.
(3)R = approximately ee (speed lever full, speed = ff)
(4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm ff=0r/min
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm ff=0r/min
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg
0000001501 LEVER
(A) Idle
(B) Full speed
(C) Base lever
(D) Accelerator lever
(E) Accelerator lever delivery position
1. Measure speed lever angle
(1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------
----------
b=(34deg)+-3deg c=21deg+-5deg
----------
----------
b=(34deg)+-3deg c=21deg+-5deg
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=7deg
----------
a=(4deg)
----------
aa=7deg
----------
a=(4deg)
Information:
Do not operate the machine if any guards or covers are missing or inadequately secured. Personnel could be seriously injured or machine damage may occur.
Observe the safe working load limits of all lifting and blocking devices and keep a safe distance from suspended/blocked loads. Personnel may be seriously injured or killed by falling loads.
Reference Section
Refer to Service Magazine, M0082326, "Diesel Exhaust Fluid (DEF) Contamination on C4.4 Machine Engines".Refer to Service Magazine, M0096547, "Diesel Exhaust Fluid (DEF) Pump Filter Maintenance on Certain C4.4 Machine Engines".Refer to Special Instruction, M0096185, "Diesel Exhaust Fluid (DEF) Pump Diesel Contamination Test on Certain C4.4 Engines".Problem
There have been instances of returned DEF pumps that have no fault found or indicating contamination.Resolution
Complete the form below and attach to any SIMSi claim in addition to a Product Status Report (PSR) from before any troubleshooting was performed or any diagnostic codes were cleared.
Use the electronic service tool to download a PSR with Histograms.
Enter the diagnostic codes that require troubleshooting: ___
Perform the correct troubleshooting procedure for any active diagnostic codes. Refer to Troubleshooting, Diagnostic Trouble Codes.
If the troubleshooting procedure requests that the DEF is tested for contamination or concentration , record the results in Table 1 and Table 2.
For other DEF-related troubleshooting procedures, follow the applicable troubleshooting steps and record the results in Table 3.
Table 1
DEF Contamination
Step Instruction Completed Result Units
1 Perform the test procedure for DEF contamination. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Quality - Test.
2 Compensator measurements. Refer to Special Instruction, M0096185, "Diesel Exhaust Fluid (DEF) Pump Diesel Contamination Test on Certain C4.4 Engines".
Diameter (A) mm
Length (B) mm
3 If contamination is present, confirm that DEF system has been flushed. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Tank - Flush
Table 2
DEF Concentration
Step Instruction Completed Result Units
1 Perform the test procedure for DEF concentration. Refer to Systems Operation, Testing and Adjusting, Diesel Exhaust Fluid Quality - Test. %
2 If the DEF concentration is out of specification, confirm that the DEF tank has been drained and filled with the correct specification of DEF. Refer to Operation and Maintenance Manual, Diesel Exhaust Fluid - Fill.
Table 3
DEF Troubleshooting
Step Instruction Completed Result Units
1 Latest engine and Dosing Control Unit (DCU) software has been installed. Refer to Troubleshooting, ECM Software - Install.
2 DEF lines have been checked for restrictions.
3 DEF pump has been checked for restrictions.
4 DEF injector has been checked for restrictions.
5 DEF lines have been inspected for leaks.
6 Confirm the DEF pressure. Refer to Troubleshooting, DEF Pressure Does Not Respond. kPa
7 DEF dosing system accuracy test has been performed. Refer to Troubleshooting, Aftertreatment SCR System Dosing - Test.
8 DEF pump filter replaced.
9 "Aftertreatment System Functional Test" performed. Refer to Troubleshooting, Service Tool Features.
Have questions with 101608-1260?
Group cross 101608-1260 ZEXEL
Mitsubishi
Mitsubishi
Mitsubishi
Mitsubishi
101608-1260
INJECTION-PUMP ASSEMBLY