Information injection-pump assembly
ZEXEL
101609-9300
1016099300
MITSUBISHI-HEAV
3436501060
3436501060
Rating:
Service parts 101609-9300 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}
15.
NOZZLE SET
Include in #1:
101609-9300
as INJECTION-PUMP ASSEMBLY
Include in #2:
104110-1001
as _
Cross reference number
ZEXEL
101609-9300
1016099300
MITSUBISHI-HEAV
3436501060
3436501060
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
131424-5720
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
3.7
3.65
3.75
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
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
8.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
78
77
79
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.4+-0.5
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
12
10.7
13.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
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: RAL
(4)Set idle sub-spring
(5)Main spring setting
----------
K=6 RAL=9.3+0.2mm
----------
----------
K=6 RAL=9.3+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=70mm
----------
a=6.5deg+-5deg b=17.5deg+-5deg
----------
aa=70mm
----------
a=6.5deg+-5deg b=17.5deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Contacts outer boss.
(2)Contacts inner boss.
(3)Use the hole at R = aa
(4)Normal
----------
aa=60mm
----------
a=53deg+-5deg b=26.5deg+-5deg c=(9deg)
----------
aa=60mm
----------
a=53deg+-5deg b=26.5deg+-5deg c=(9deg)
0000001501 I/P WITH LOAD PLUNGER ADJ
Load plunger-equipped pump adjustment
1. Adjust the variation between cylinders and the injection quantity.
2. At Full point A, adjust the pre-stroke to the specified value.
3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
----------
----------
----------
----------
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)After adjusting the injection quantity, adjust at rack position bb.
----------
aa=6deg bb=8.8mm
----------
a=(110deg)
----------
aa=6deg bb=8.8mm
----------
a=(110deg)
Information:
Problem
The lift adjusting screw may break in certain 7E3969 1W5829, 4W8483, and 7W3710 Fuel Injection Nozzles with date codes of A9 thru M9, and A0 thru L0. If the adjusting screw breaks the adjustment screw in the nozzle can vibrate toward the fuel shutoff position which can result in the following symptoms:
A) Low Horsepower. The affected engine may not reach rated rpm. The engine does not emit any excessive black smoke. The engine may or may not have a detectable miss.B) Low Horsepower. The affected engine may not reach the rated rpm. The engine may emit heavy black smoke.C) Low Idle Misfire. Some engines run at rated speed but have a miss when idling.Affected Product
Model & Identification Number
3208 (30A3876-4565; 90N72172-73198; 75V10138-10420; 62W58913-Up; 01Z19535-22859; 03Z9391-10398; 51Z79496-80434)
Parts Needed
8* - 7E3969 Nozzle8* - 9L6969 Nozzle8* - 9N3299 Nozzle8* - 1W5829 Nozzle8* - 4W1819 Nozzle8* - 4W8483 Nozzle8* - 7W3710 Nozzle*Refer to your engine arrangement for the correct part number.Action Required
Parts Stock
Inspect all 7E3969, 9L6969, 9N3299, 1W5829, 4W1819, 4W8483, and 7W3710, Fuel Injection Nozzles for the date code as shown in the illustration. If date codes of A9, B9, C9, D9, E9, F9, G9, H9, I9, J9, K9, L9, M9, A0, B0, C0, D0, E0, F0, G0, H0, I0, J0, K0, or L0 are on the nozzles, remove the nozzles from parts stock.
Fuel Injection Nozzle Date Codes If the part number or date code is difficult to read, apply white paint to the area and carefully remove any excess.
Affected Product
If possible, isolate the cylinder(s) with a failed nozzle by loosening the fuel line nuts. The nozzle cap(s) may be removed to check for a broken lift adjustment screw.
Check the date code on the replacement nozzles before installing them. The date code on the flat of the nozzle nut must be M0, A1, B1, C1, or higher. Some nozzles will have a date code above the part number and a second date code on another flat of the nozzle nut. The second date code will continue two letters and a number. The first letter will always be an "R". The second letter is for the month "A-M". The number will be 0 for 1990 or 1 for 1991.
Any nozzle with a date code between A9 and M9 or A0 and L0 without the second date code should not be used.
On a twin engine marine installation, install new nozzles in both engines.
Service Claim Allowances
Parts Stock
Submit one claim for all 7E3969, 9L6969, 9N3299, 1W5829, 4W1819, 4W8483, and 7W3710, Fuel Injection Nozzles removed from parts stock.
Affected Product
This is a 5-hour job.
On a twin engine marine installation, a separate claim must be filed for the second engine.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
The lift adjusting screw may break in certain 7E3969 1W5829, 4W8483, and 7W3710 Fuel Injection Nozzles with date codes of A9 thru M9, and A0 thru L0. If the adjusting screw breaks the adjustment screw in the nozzle can vibrate toward the fuel shutoff position which can result in the following symptoms:
A) Low Horsepower. The affected engine may not reach rated rpm. The engine does not emit any excessive black smoke. The engine may or may not have a detectable miss.B) Low Horsepower. The affected engine may not reach the rated rpm. The engine may emit heavy black smoke.C) Low Idle Misfire. Some engines run at rated speed but have a miss when idling.Affected Product
Model & Identification Number
3208 (30A3876-4565; 90N72172-73198; 75V10138-10420; 62W58913-Up; 01Z19535-22859; 03Z9391-10398; 51Z79496-80434)
Parts Needed
8* - 7E3969 Nozzle8* - 9L6969 Nozzle8* - 9N3299 Nozzle8* - 1W5829 Nozzle8* - 4W1819 Nozzle8* - 4W8483 Nozzle8* - 7W3710 Nozzle*Refer to your engine arrangement for the correct part number.Action Required
Parts Stock
Inspect all 7E3969, 9L6969, 9N3299, 1W5829, 4W1819, 4W8483, and 7W3710, Fuel Injection Nozzles for the date code as shown in the illustration. If date codes of A9, B9, C9, D9, E9, F9, G9, H9, I9, J9, K9, L9, M9, A0, B0, C0, D0, E0, F0, G0, H0, I0, J0, K0, or L0 are on the nozzles, remove the nozzles from parts stock.
Fuel Injection Nozzle Date Codes If the part number or date code is difficult to read, apply white paint to the area and carefully remove any excess.
Affected Product
If possible, isolate the cylinder(s) with a failed nozzle by loosening the fuel line nuts. The nozzle cap(s) may be removed to check for a broken lift adjustment screw.
Check the date code on the replacement nozzles before installing them. The date code on the flat of the nozzle nut must be M0, A1, B1, C1, or higher. Some nozzles will have a date code above the part number and a second date code on another flat of the nozzle nut. The second date code will continue two letters and a number. The first letter will always be an "R". The second letter is for the month "A-M". The number will be 0 for 1990 or 1 for 1991.
Any nozzle with a date code between A9 and M9 or A0 and L0 without the second date code should not be used.
On a twin engine marine installation, install new nozzles in both engines.
Service Claim Allowances
Parts Stock
Submit one claim for all 7E3969, 9L6969, 9N3299, 1W5829, 4W1819, 4W8483, and 7W3710, Fuel Injection Nozzles removed from parts stock.
Affected Product
This is a 5-hour job.
On a twin engine marine installation, a separate claim must be filed for the second engine.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.