Information injection-pump assembly
BOSCH
F 019 Z10 297
f019z10297
ZEXEL
101608-6522
1016086522
MITSUBISHI
ME441718
me441718
Rating:
Service parts 101608-6522 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME440837
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Include in #1:
101608-6522
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-0516
as _
Cross reference number
BOSCH
F 019 Z10 297
f019z10297
ZEXEL
101608-6522
1016086522
MITSUBISHI
ME441718
me441718
Zexel num
Bosch num
Firm num
Name
101608-6522
F 019 Z10 297
ME441718 MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D34TL K 14BE INJECTION PUMP ASSY PE6A PE
6D34TL K 14BE INJECTION PUMP ASSY PE6A PE
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Drive side NO.1
Drive 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
A
Rack position
10
Pump speed
r/min
1085
1085
1085
Average injection quantity
mm3/st.
95
94
96
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
80
80
Boost pressure
mmHg
600
600
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.3+-0.5
Pump speed
r/min
515
515
515
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
E
Rack position
10.2++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
65
65
70
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
900
900
900
Rack position
R1-1.05
Boost pressure
kPa
24
17.3
30.7
Boost pressure
mmHg
180
130
230
Boost compensator adjustment_02
Pump speed
r/min
900
900
900
Rack position
R1(10)
Boost pressure
kPa
70.6
67.9
73.3
Boost pressure
mmHg
530
510
550
Timer adjustment
Pump speed
r/min
0
Advance angle
deg.
3
2
3
Load
0/4
Timer adjustment_02
Pump speed
r/min
650+-25
Advance angle
deg.
3
2
3
Load
0/4
Remarks
Start
Start
Timer adjustment_03
Pump speed
r/min
750+-25
Advance angle
deg.
0
0
0
Load
0/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Boost compensator stroke: BCL
----------
K=12 BCL=1.05+-0.1mm
----------
----------
K=12 BCL=1.05+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Base lever only
----------
----------
a=3.5deg+-5deg b=19deg+-5deg
----------
----------
a=3.5deg+-5deg b=19deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)Normal
----------
aa=0r/min bb=4-0.5mm
----------
a=14deg+-5deg b=(48deg)
----------
aa=0r/min bb=4-0.5mm
----------
a=14deg+-5deg b=(48deg)
Timing setting
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=10deg
----------
a=(130deg)
----------
aa=10deg
----------
a=(130deg)
Information:
Crankshaft fillet finishing dimension (2)
(a) When regrinding journals of the crankshaft, be sure to refinish all journals to the same dimension.(b) Finish the fillet radius to R3 mm [0.1181 in.].
Inspection of Oil Seal Contact Surface
Check the oil seal contact surface of the crankshaft back-end, and, if the crankshaft face has been excessively worn by the oil seal, replace the oil seal and oil sleeve with replacement parts.
Inspection of oil seal contact surface(1) Installation of oil seal sleeveTo install the oil seal sleeve, coat the inner surface of the sleeve with oil, and use the crankshaft sleeve installer for driving the sleeve into place.
Be careful not to dent or scratch the outer surface of the oil seal sleeve.
When the oil seal slinger becomes worn after engine operation, remove the oil seal sleeve by following the procedure below, and replace it with a replacement oil seal assembly (oil seal and oil seal sleeve).
Inspection of oil seal sleeve
Inspection of oil seal contact surface(2) Removal of oil seal sleeveAt three locations on the sleeve end face, hold a chisel at a right angle to the sleeve and strike with a hammer, and remove the sleeve when it becomes loose.If this method does not allow the removal of the sleeve, hold the chisel in the axial direction and lightly tap to expand and loosen the sleeve.
Be careful not to damage the crankshaft with the chisel when removing the oil seal sleeve.
Removal of oil seal sleeveMeasurement of Crankshaft Deflection
Support the crankshaft on its front and rear journals in V-blocks, and measure the runout at the center journal with a dial gage. Compare the amount of runout with the standard. If the runout is small, correct by grinding. If the runout is large, straighten with a press.If the runout exceeds the limit significantly, replace the crankshaft.
Measurement of crankshaft deflectionRemoval of Crankshaft Gear
Use the gear puller to remove the crankshaft gear. Do not remove the crankshaft gear unless the crankshaft or gear is replaced.
Removal of crankshaft gearInstallation of Crankshaft Gear
(1) Heat the gear to a temperature of 100 to 150 °C [212 to 302 °F].(2) Install the key to the crankshaft.(3) Align the gear with key and insert the gear fully.
Installation of crankshaft gearMeasurement of Cylinder Bore
(1) Using a cylinder gage, measure the cylinder bore and cylindricity. If the limit value is exceeded even at one place, bore all cylinders and replace the pistons and piston rings with oversize pistons and piston rings. Measure at three locations each in directions A and B shown in the diagram.
Measurement of inside diameter of cylinder(2) Boring of cylinders(a) Since there are two piston oversizes (0.25 mm [0.0098 in.] and 0.50 mm [0.0197 in.] oversize) as indicated above, determine the appropriate piston size to be used based on the largest cylinder bore diameter.(b) Measure the outside diameter of the piston to be used. The piston diameter measuring points are shown in the diagram.(c) Based on the measurements of the piston outside diameter, calculate the finishing dimension to be achieved by
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Mitsubishi
Mitsubishi
Mitsubishi
101608-6522
F 019 Z10 297
ME441718
INJECTION-PUMP ASSEMBLY
6D34TL
6D34TL