Information injection-pump assembly
ZEXEL
104741-3020
1047413020
MITSUBISHI
ME200201
me200201
Rating:
Cross reference number
ZEXEL
104741-3020
1047413020
MITSUBISHI
ME200201
me200201
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113orSAEJ967d
1404 Test oil ISO4113orSAEJ967d
Test oil temperature
degC
45
45
50
Nozzle
105780-0060
Bosch type code
NP-DN0SD1510
Nozzle holder
105780-2150
Opening pressure
MPa
13
13
13.3
Opening pressure
kgf/cm2
133
133
136
Injection pipe
157805-7320
Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450
Inside diameter - outside diameter - length (mm) mm 2-6-450
Joint assembly
157641-4720
Tube assembly
157641-4020
Transfer pump pressure
kPa
20
20
20
Transfer pump pressure
kgf/cm2
0.2
0.2
0.2
Direction of rotation (viewed from drive side)
Right R
Right R
(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF. OFF
With S/T O-ring; S/T OFF. OFF
Injection timing adjustment
Pump speed
r/min
550
550
550
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
53.5
53
54
Difference in delivery
mm3/st.
4
Basic
*
Oil temperature
degC
50
48
52
Remarks
NA
NA
Injection timing adjustment_02
Pump speed
r/min
600
600
600
Boost pressure
kPa
31.3
30
32.6
Boost pressure
mmHg
235
225
245
Average injection quantity
mm3/st.
68.2
67.7
68.7
Difference in delivery
mm3/st.
5.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
CBS
CBS
Injection timing adjustment_03
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Average injection quantity
mm3/st.
75.6
75.1
76.1
Difference in delivery
mm3/st.
6
Basic
*
Oil temperature
degC
50
48
52
Remarks
Full
Full
Injection timing adjustment_04
Pump speed
r/min
550
550
550
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
53.5
52.5
54.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
NA
NA
Injection timing adjustment_05
Pump speed
r/min
600
600
600
Boost pressure
kPa
31.3
30
32.6
Boost pressure
mmHg
235
225
245
Average injection quantity
mm3/st.
68.2
67.2
69.2
Basic
*
Oil temperature
degC
50
48
52
Remarks
CBS
CBS
Injection timing adjustment_06
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Average injection quantity
mm3/st.
75.6
74.6
76.6
Difference in delivery
mm3/st.
6.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
Full
Full
Injection timing adjustment_07
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Average injection quantity
mm3/st.
71.4
67.4
75.4
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
2475
2475
2475
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Average injection quantity
mm3/st.
33
30
36
Difference in delivery
mm3/st.
5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_02
Pump speed
r/min
2475
2475
2475
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Average injection quantity
mm3/st.
33
28
38
Difference in delivery
mm3/st.
5.5
Basic
*
Oil temperature
degC
55
52
58
Injection quantity adjustment_03
Pump speed
r/min
2800
2800
2800
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Average injection quantity
mm3/st.
8
Oil temperature
degC
55
52
58
Governor adjustment
Pump speed
r/min
365
365
365
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
10.5
8.5
12.5
Difference in delivery
mm3/st.
2
Basic
*
Oil temperature
degC
48
46
50
Governor adjustment_02
Pump speed
r/min
365
365
365
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
10.5
8
13
Difference in delivery
mm3/st.
2.5
Basic
*
Oil temperature
degC
48
46
50
Timer adjustment
Pump speed
r/min
100
100
100
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
50
40
60
Basic
*
Oil temperature
degC
48
46
50
Remarks
IDLE
IDLE
Timer adjustment_02
Pump speed
r/min
100
100
100
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
50
40
60
Basic
*
Oil temperature
degC
48
46
50
Speed control lever angle
Pump speed
r/min
365
365
365
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
48
46
50
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
0000000901
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Overflow quantity with S/T ON
cm3/min
850
720
980
Overflow quantity with S/T OFF
cm3/min
930
800
1060
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Pressure with S/T ON
kPa
559
520
598
Pressure with S/T ON
kgf/cm2
5.7
5.3
6.1
Pressure with S/T OFF
kPa
481
461
501
Pressure with S/T OFF
kgf/cm2
4.9
4.7
5.1
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_02
Pump speed
r/min
700
700
700
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Pressure with S/T ON
kPa
422
373
471
Pressure with S/T ON
kgf/cm2
4.3
3.8
4.8
Pressure with S/T OFF
kPa
284
235
333
Pressure with S/T OFF
kgf/cm2
2.9
2.4
3.4
Oil temperature
degC
50
48
52
Stop lever angle_03
Pump speed
r/min
800
800
800
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Pressure with S/T OFF
kPa
353
304
402
Pressure with S/T OFF
kgf/cm2
3.6
3.1
4.1
Oil temperature
degC
50
48
52
Stop lever angle_04
Pump speed
r/min
900
900
900
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Pressure with S/T OFF
kPa
392
353
431
Pressure with S/T OFF
kgf/cm2
4
3.6
4.4
Oil temperature
degC
50
48
52
Stop lever angle_05
Pump speed
r/min
1000
1000
1000
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Pressure with S/T OFF
kPa
422
383
461
Pressure with S/T OFF
kgf/cm2
4.3
3.9
4.7
Oil temperature
degC
50
48
52
Stop lever angle_06
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Pressure with S/T ON
kPa
530
481
579
Pressure with S/T ON
kgf/cm2
5.4
4.9
5.9
Pressure with S/T OFF
kPa
451
412
490
Pressure with S/T OFF
kgf/cm2
4.6
4.2
5
Oil temperature
degC
50
48
52
Stop lever angle_07
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Pressure with S/T ON
kPa
559
510
608
Pressure with S/T ON
kgf/cm2
5.7
5.2
6.2
Pressure with S/T OFF
kPa
481
452
510
Pressure with S/T OFF
kgf/cm2
4.9
4.6
5.2
Basic
*
Oil temperature
degC
50
48
52
Stop lever angle_08
Pump speed
r/min
2000
2000
2000
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Pressure with S/T ON
kPa
696
647
745
Pressure with S/T ON
kgf/cm2
7.1
6.6
7.6
Pressure with S/T OFF
kPa
628
589
667
Pressure with S/T OFF
kgf/cm2
6.4
6
6.8
Oil temperature
degC
50
48
52
0000001101
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Timer stroke with S/T ON
mm
6.7
6.2
7.2
Timer stroke with S/T OFF
mm
4.7
4.5
4.9
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
700
700
700
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Timer stroke with S/T ON
mm
3.3
2.6
4
Timer stroke with S/T OFF
mm
0.8
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Timer stroke with S/T ON
mm
6.7
6
7.4
Timer stroke with S/T OFF
mm
4.7
4.3
5.1
Basic
*
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
2300
2300
2300
Boost pressure
kPa
73.3
72
74.6
Boost pressure
mmHg
550
540
560
Timer stroke with S/T OFF
mm
9.8
9.3
10.2
Oil temperature
degC
52
50
54
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
Timing setting
K dimension
mm
3.3
3.2
3.4
KF dimension
mm
6.01
5.91
6.11
MS dimension
mm
0.7
0.6
0.8
BCS stroke
mm
4.5
4.3
4.7
Control lever angle alpha
deg.
59
55
63
Control lever angle beta
deg.
42
37
47
Test data Ex:
0000001801 POTENTIOMETER ADJUSTMENT
Adjustment of the potentiometer
Vi:Applied voltage
C:Position of the control lever
N:Pump speed
V:Output voltage
Q:Injection quantity
A:Adjusting point
C1:Idling
C2:Full speed
----------
----------
V1=1.6+-0.03(V) V2=(8.6(V)) Vi=10(V)
----------
----------
V1=1.6+-0.03(V) V2=(8.6(V)) Vi=10(V)
0000001901 V-FICD ADJUSTMENT
Adjustment of the two stage actuator (FICD).
1. Install the 2-stage actuator on the injection pump.
2. With the control lever in the idle position adjust using the rod position adjusting nut so that the clearance between control lever and the rod is L1.
3. The actuator stroke is adjusted on the engine.
4. Rod position's allowable angle of rotation: c
(C) Rod position adjusting nut
(D) Stroke adjusting nut
(E) Actuator stroke
----------
L1=1+1(mm) c=+-20(deg)
----------
L1=1+1(mm) SW1=SW7 SW2=SW8 T1=1.4~2.0(Nm)(0.14~0.2(kgfm)) T2=3.4~4.9(Nm)(0.35~0.5(kgfm)) a=20(deg) b=20(deg)
----------
L1=1+1(mm) c=+-20(deg)
----------
L1=1+1(mm) SW1=SW7 SW2=SW8 T1=1.4~2.0(Nm)(0.14~0.2(kgfm)) T2=3.4~4.9(Nm)(0.35~0.5(kgfm)) a=20(deg) b=20(deg)
0000002001 W-FICD LEVER ADJUSTMENT
2. Adjustment of the W-FICD
(1)Insert a block gauge L determined from the graph between the control lever (B) and the idling set screw (A).
(2)Fix bolt (E) in the position where W-FICD lever (C) contacts the control lever (D). (Tighten to torque T.)
(3)Remove the block gauge and shims after completing adjustment.
Caution: The temperature of the wax at adjustment must not exceed a.
G = control lever L dimension (control lever position)
H = temperature t (deg C)
----------
L=L+-0.3mm T=3.4~4.9N-m(0.35~0.5kgf-m) a=35degC
----------
L=-0.115t+4.6(0<=t(degC))
----------
L=L+-0.3mm T=3.4~4.9N-m(0.35~0.5kgf-m) a=35degC
----------
L=-0.115t+4.6(0<=t(degC))
Information:
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
There have been some instances of the following active diagnostic codes:
651-6 Engine Injector Cylinder #01 : Current Above Normal
652-6 Engine Injector Cylinder #02 : Current Above Normal
653-6 Engine Injector Cylinder #03 : Current Above Normal
654-6 Engine Injector Cylinder #04 : Current Above NormalThe engine will be derated and will be difficult to start.Solution
Follow the correct troubleshooting procedure for the active diagnostic codes. Refer to Troubleshooting, Injector Solenoid - Test.
If the troubleshooting procedure identifies suspect injectors, use the electronic service tool to generate a Product Status Report (PSR). Select the "Histogram" option when generating the PSR.
Install replacement 418-3229 Fuel Injector Gp, as required. Refer to Disassembly and Assembly, Electronic Unit Injector - Remove and Disassembly and Assembly, Electronic Unit Injector - Install.
Use 169-7372 Fluid Sampling Bottles to obtain a fuel sample from the following locations:
Machine fuel tank ( 355 mL (12 oz)
Bulk fuel supply tank ( 355 mL (12 oz)Analyze the fuel sample. The fuel samples will need to be analyzed for the following properties:
Lubricity Wear Scar - "ASTM D6079" or "ISO 12156"
Density at 15° C (59° F) - "ASTM D1298", "ASTM D4052", "ISO 3675", or "ISO 12185"
Kinematic Viscosity at 40° C (104° F) - "ASTM D445", "ISO 3448", or "ISO 3104"
Sulfur - "ASTM D4294", "ASTM D5185", "ASTM D5453", "ASTM D26222", "ISO 20846", or "ISO 20884"
Water by Distillation - "ASTM D95", "ASTM D6304", "ASTM D2709", "ASTM D1796", or "ISO3734"
Cloud Point - "ASTM D2500" or "ISO 3015"
FAME - "EN 14078", "ASTM D7806", or "ASTM D7371"
Oxidation Stability - "EN 14112"
Copper - "ASTM D7111"
Sodium - "ASTM D7111"
Zinc - "ASTM D7111"
Calcium - "ASTM D7111"
Potassium - "ASTM D7111"Provide the results of the fuel sample.
Retain any removed injectors. The injectors will be requested for return through the "Send It Back" (SIB) process.
Submit the PSR along with TIB Media number, M0085259, and CPI number 386169 through "CPI Feedback" within the Service Information Management System (SIMSi).
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
There have been some instances of the following active diagnostic codes:
651-6 Engine Injector Cylinder #01 : Current Above Normal
652-6 Engine Injector Cylinder #02 : Current Above Normal
653-6 Engine Injector Cylinder #03 : Current Above Normal
654-6 Engine Injector Cylinder #04 : Current Above NormalThe engine will be derated and will be difficult to start.Solution
Follow the correct troubleshooting procedure for the active diagnostic codes. Refer to Troubleshooting, Injector Solenoid - Test.
If the troubleshooting procedure identifies suspect injectors, use the electronic service tool to generate a Product Status Report (PSR). Select the "Histogram" option when generating the PSR.
Install replacement 418-3229 Fuel Injector Gp, as required. Refer to Disassembly and Assembly, Electronic Unit Injector - Remove and Disassembly and Assembly, Electronic Unit Injector - Install.
Use 169-7372 Fluid Sampling Bottles to obtain a fuel sample from the following locations:
Machine fuel tank ( 355 mL (12 oz)
Bulk fuel supply tank ( 355 mL (12 oz)Analyze the fuel sample. The fuel samples will need to be analyzed for the following properties:
Lubricity Wear Scar - "ASTM D6079" or "ISO 12156"
Density at 15° C (59° F) - "ASTM D1298", "ASTM D4052", "ISO 3675", or "ISO 12185"
Kinematic Viscosity at 40° C (104° F) - "ASTM D445", "ISO 3448", or "ISO 3104"
Sulfur - "ASTM D4294", "ASTM D5185", "ASTM D5453", "ASTM D26222", "ISO 20846", or "ISO 20884"
Water by Distillation - "ASTM D95", "ASTM D6304", "ASTM D2709", "ASTM D1796", or "ISO3734"
Cloud Point - "ASTM D2500" or "ISO 3015"
FAME - "EN 14078", "ASTM D7806", or "ASTM D7371"
Oxidation Stability - "EN 14112"
Copper - "ASTM D7111"
Sodium - "ASTM D7111"
Zinc - "ASTM D7111"
Calcium - "ASTM D7111"
Potassium - "ASTM D7111"Provide the results of the fuel sample.
Retain any removed injectors. The injectors will be requested for return through the "Send It Back" (SIB) process.
Submit the PSR along with TIB Media number, M0085259, and CPI number 386169 through "CPI Feedback" within the Service Information Management System (SIMSi).