Information injection-pump assembly
ZEXEL
104742-3021
1047423021
MITSUBISHI-HEAV
32A6527330
32a6527330
Rating:
Cross reference number
ZEXEL
104742-3021
1047423021
MITSUBISHI-HEAV
32A6527330
32a6527330
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
Timer measuring device installation position
Low pressure side LOW PRESSURE SIDE
Low pressure side LOW PRESSURE SIDE
Injection timing adjustment
Pump speed
r/min
900
900
900
Boost pressure
kPa
33.3
32
34.6
Boost pressure
mmHg
250
240
260
Average injection quantity
mm3/st.
109.3
108.8
109.8
Basic
*
Oil temperature
degC
50
48
52
Remarks
CBS
CBS
Injection timing adjustment_02
Pump speed
r/min
900
900
900
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
116.2
115.7
116.7
Difference in delivery
mm3/st.
11
Basic
*
Oil temperature
degC
50
48
52
Remarks
Full
Full
Injection timing adjustment_03
Pump speed
r/min
500
500
500
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
77.8
70.8
84.8
Oil temperature
degC
48
46
50
Injection timing adjustment_04
Pump speed
r/min
900
900
900
Boost pressure
kPa
33.3
32
34.6
Boost pressure
mmHg
250
240
260
Average injection quantity
mm3/st.
109.3
106.8
111.8
Basic
*
Oil temperature
degC
50
48
52
Remarks
CBS
CBS
Injection timing adjustment_05
Pump speed
r/min
900
900
900
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
116.2
113.7
118.7
Difference in delivery
mm3/st.
11.5
Basic
*
Oil temperature
degC
50
48
52
Remarks
Full
Full
Injection timing adjustment_06
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
125.3
119.8
130.8
Oil temperature
degC
50
48
52
Injection timing adjustment_07
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
123.7
118.2
129.2
Oil temperature
degC
50
48
52
Injection quantity adjustment
Pump speed
r/min
1425
1425
1425
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
5
Basic
*
Oil temperature
degC
50
48
52
Injection quantity adjustment_02
Pump speed
r/min
1425
1425
1425
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
6.5
Basic
*
Oil temperature
degC
50
48
52
Injection quantity adjustment_03
Pump speed
r/min
1300
1300
1300
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
115.4
115.4
Oil temperature
degC
50
48
52
Remarks
(check)
(check)
Governor adjustment
Pump speed
r/min
525
525
525
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
7.2
5.2
9.2
Difference in delivery
mm3/st.
3
Basic
*
Oil temperature
degC
50
48
52
Governor adjustment_02
Pump speed
r/min
525
525
525
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
7.2
4.7
9.7
Difference in delivery
mm3/st.
3.5
Basic
*
Oil temperature
degC
50
48
52
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.
103
78
128
Basic
*
Oil temperature
degC
48
46
50
Remarks
Full
Full
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.
103
78
128
Oil temperature
degC
48
46
50
Remarks
Full
Full
Speed control lever angle
Pump speed
r/min
525
525
525
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
50
48
52
Remarks
Magnet OFF at idling position
Magnet OFF at idling position
Speed control lever angle_02
Pump speed
r/min
525
525
525
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Average injection quantity
mm3/st.
0
0
0
Oil temperature
degC
50
48
52
Remarks
Magnet ON at idling position and stop lever operate
Magnet ON at idling position and stop lever operate
0000000901
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Overflow quantity with S/T ON
cm3/min
540
410
670
Oil temperature
degC
50
48
52
Stop lever angle
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Pressure with S/T ON
kPa
736
687
785
Pressure with S/T ON
kgf/cm2
7.5
7
8
Pressure with S/T OFF
kPa
539
519
559
Pressure with S/T OFF
kgf/cm2
5.5
5.3
5.7
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
Stop lever angle_02
Pump speed
r/min
900
900
900
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Pressure with S/T OFF
kPa
392
343
441
Pressure with S/T OFF
kgf/cm2
4
3.5
4.5
Oil temperature
degC
50
48
52
Stop lever angle_03
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Pressure with S/T OFF
kPa
490
441
539
Pressure with S/T OFF
kgf/cm2
5
4.5
5.5
Oil temperature
degC
50
48
52
Stop lever angle_04
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Pressure with S/T ON
kPa
736
677
795
Pressure with S/T ON
kgf/cm2
7.5
6.9
8.1
Pressure with S/T OFF
kPa
539
510
568
Pressure with S/T OFF
kgf/cm2
5.5
5.2
5.8
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
0000001101
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Timer stroke with S/T ON
mm
4.2
3.7
4.7
Timer stroke with S/T OFF
mm
2.5
2.3
2.7
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
_02
Pump speed
r/min
900
900
900
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Timer stroke with S/T OFF
mm
0.9
0.2
1.6
Oil temperature
degC
50
48
52
_03
Pump speed
r/min
1100
1100
1100
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Timer stroke with S/T OFF
mm
2
1.4
2.6
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Timer stroke with S/T ON
mm
4.2
3.5
4.9
Timer stroke with S/T OFF
mm
2.5
2.1
2.9
Basic
*
Oil temperature
degC
50
48
52
Remarks
OFF
OFF
0000001201
Max. applied voltage
V
8
8
8
Test voltage
V
13
12
14
0000001401
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
99
97
101
Timer stroke TA
mm
0
0
0.3
Timer stroke variation dT
mm
2.5
2.5
2.5
Basic
*
Oil temperature
degC
50
48
52
_02
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
116
114
118
Timer stroke TA
mm
2.3
2.3
Timer stroke variation dT
mm
0.2
0.2
0.2
Oil temperature
degC
50
48
52
Remarks
(check)
(check)
_03
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
99
96.5
101.5
Timer stroke TA
mm
0
0
0.5
Timer stroke variation dT
mm
2.5
2.5
2.5
Basic
*
Oil temperature
degC
50
48
52
_04
Pump speed
r/min
1250
1250
1250
Boost pressure
kPa
66.7
65.4
68
Boost pressure
mmHg
500
490
510
Average injection quantity
mm3/st.
15
12.5
17.5
Timer stroke TA
mm
3.1
2.3
3.9
Timer stroke variation dT
mm
1.1
1.1
1.1
Oil temperature
degC
50
48
52
Timing setting
K dimension
mm
3.1
3
3.2
KF dimension
mm
5.5
5.4
5.6
MS dimension
mm
0.6
0.5
0.7
BCS stroke
mm
1.6
1.5
1.7
Pre-stroke
mm
0.45
0.43
0.47
Control lever angle alpha
deg.
16
12
20
Control lever angle beta
deg.
29
24
34
Test data Ex:
0000001801 TAMPER PROOF
Tamperproof installation procedure
A:Position of break
B:Rubber vibration damper
C:Nut
D:Cap
E:Nut
F:Nut
G:Cap
L1:Inspection dimension
Fig. 1 Regulating valve seal
1) Target breaking torque T1
2) Maximum allowable breaking torque T2
3) Because the cap and the regulating valve are fixed using the MEC process, the bolt cannot be loosened after the bolt has been broken.
Fig.2 Full load adjusting screw
1) Confirm the position of the rubber vibration damper (B) and then tighten nut (C) to the torque T3.
Fig. 3 Maximum speed adjusting screw
1) Tighten nut (E) to the torque T4.
2) To prevent nut (E) from turning together, fix (E) using the tool, then tighten nut (F) to torque T4.
----------
L1=23~28mm T1=5~6.9N-m(0.5~0.69kgf-m) T2=9N-m(0.9kgf-m) T3=7~9N-m(0.7~0.9kgf-m) T4=6~9N-m(0.6~0.9kgf-m)
----------
L1=23~28mm
----------
L1=23~28mm T1=5~6.9N-m(0.5~0.69kgf-m) T2=9N-m(0.9kgf-m) T3=7~9N-m(0.7~0.9kgf-m) T4=6~9N-m(0.6~0.9kgf-m)
----------
L1=23~28mm
Information:
Warning Operation
Two flashing warning lamps and an alarm inform the operator that: * An ether cylinder is empty.* Both ether cylinders are empty.* A noncritical fault is present.* A critical fault is present.The warning lamps and alarm can be tested by placing the ether system switch in the Test/Disable position. The warning alarm will turn ON for two seconds and the warning lamps will remain ON continuously until the switch is returned to the Auto position. If a solenoid valve is shorted to +BAT, the alarm sounds whenever the key switch is in the RUN or START position. The alarm beeps at the rate of approximately 1.3 seconds ON and 2.0 seconds OFF. The engine could be damaged if ether was injected before the engine is cranked.An Ether Cylinder Is Empty
One of the two warning lamps inform the operator when an ether cylinder is empty. The lamp flashes at the rate of 1.5 Hz (flashes per second) with equal ON and OFF times. The lamps and ether solenoid assemblies are correspondingly marked 1 and 2. When empty ether cylinder warning lamp 1 is flashing, ether cylinder 1 needs replaced. When empty ether cylinder warning lamp 2 is flashing, ether cylinder 2 needs replaced. (On 3516 engines, both ether cylinders of the set need replaced.) The lamps stop flashing when the reset switch is activated during ether cylinder replacement. The empty ether cylinder warning lamp will also flash if there is no ether cylinder installed.Both Ether Cylinders Are Empty
When both ether cylinders are empty (on 3516 engines, both ether cylinder sets), both empty ether cylinder warning lamps and the alarm are activated. Empty ether cylinder warning lamps 1 and 2 flash at the same time, at the rate of 1.5 Hz (flashes per second). The alarm also sounds, during the ether injection time, approximately 1.3 seconds ON and 2.0 seconds OFF.A Noncritical Fault Is Present
When a noncritical fault is present, both empty ether cylinder warning lamps are activated. Empty ether cylinder warning lamps 1 and 2 flash alternately (taking turns ON and OFF) at the rate of 3.0 Hz (flashes per second). The system continues to operate during a noncritical fault.A Critical Fault Is Present
When a critical fault is present. both empty ether cylinder warning lamps and the alarm are activated. Empty ether cylinder warning lamps 1 and 2 flash alternately (taking turns ON and OFF) at the rate of 3.0 Hz (flashes per second). The alarm also sounds, during the ether injection time, approximately 1.3 seconds ON and 2.0 seconds OFF. If possible, ether injections are disabled during a critical fault.Diagnostic Operation
Ether Injection Control DiagnosticsThe ether injection control has diagnostic capabilities to assist in troubleshooting. The control detects and records faults that occur to the system. During a critical fault, if possible, the control disables ether injection. During a noncritical fault, the control takes alternate action so that the system continues to function.The diagnostic display, on the ether injection control, displays a code which represents the fault that
Two flashing warning lamps and an alarm inform the operator that: * An ether cylinder is empty.* Both ether cylinders are empty.* A noncritical fault is present.* A critical fault is present.The warning lamps and alarm can be tested by placing the ether system switch in the Test/Disable position. The warning alarm will turn ON for two seconds and the warning lamps will remain ON continuously until the switch is returned to the Auto position. If a solenoid valve is shorted to +BAT, the alarm sounds whenever the key switch is in the RUN or START position. The alarm beeps at the rate of approximately 1.3 seconds ON and 2.0 seconds OFF. The engine could be damaged if ether was injected before the engine is cranked.An Ether Cylinder Is Empty
One of the two warning lamps inform the operator when an ether cylinder is empty. The lamp flashes at the rate of 1.5 Hz (flashes per second) with equal ON and OFF times. The lamps and ether solenoid assemblies are correspondingly marked 1 and 2. When empty ether cylinder warning lamp 1 is flashing, ether cylinder 1 needs replaced. When empty ether cylinder warning lamp 2 is flashing, ether cylinder 2 needs replaced. (On 3516 engines, both ether cylinders of the set need replaced.) The lamps stop flashing when the reset switch is activated during ether cylinder replacement. The empty ether cylinder warning lamp will also flash if there is no ether cylinder installed.Both Ether Cylinders Are Empty
When both ether cylinders are empty (on 3516 engines, both ether cylinder sets), both empty ether cylinder warning lamps and the alarm are activated. Empty ether cylinder warning lamps 1 and 2 flash at the same time, at the rate of 1.5 Hz (flashes per second). The alarm also sounds, during the ether injection time, approximately 1.3 seconds ON and 2.0 seconds OFF.A Noncritical Fault Is Present
When a noncritical fault is present, both empty ether cylinder warning lamps are activated. Empty ether cylinder warning lamps 1 and 2 flash alternately (taking turns ON and OFF) at the rate of 3.0 Hz (flashes per second). The system continues to operate during a noncritical fault.A Critical Fault Is Present
When a critical fault is present. both empty ether cylinder warning lamps and the alarm are activated. Empty ether cylinder warning lamps 1 and 2 flash alternately (taking turns ON and OFF) at the rate of 3.0 Hz (flashes per second). The alarm also sounds, during the ether injection time, approximately 1.3 seconds ON and 2.0 seconds OFF. If possible, ether injections are disabled during a critical fault.Diagnostic Operation
Ether Injection Control DiagnosticsThe ether injection control has diagnostic capabilities to assist in troubleshooting. The control detects and records faults that occur to the system. During a critical fault, if possible, the control disables ether injection. During a noncritical fault, the control takes alternate action so that the system continues to function.The diagnostic display, on the ether injection control, displays a code which represents the fault that