Information injection-pump assembly
ZEXEL
106491-4000
1064914000
MITSUBISHI-HEAV
3636500130
3636500130
Rating:
Service parts 106491-4000 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
3636100040
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106491-4000
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106491-4000
1064914000
MITSUBISHI-HEAV
3636500130
3636500130
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-1520
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.7
3.65
3.75
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
126.5
121.5
131.5
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.2+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
18
15
21
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
230
230
240
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
570--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
520
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
4
3.5
4.5
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)Idle spring not operating.
(4)RACK LIMIT
----------
K=16
----------
----------
K=16
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=6deg+-5deg b=32deg+-3deg c=20deg+-5deg
----------
----------
a=6deg+-5deg b=32deg+-3deg c=20deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=50deg+-5deg b=53deg+-5deg
----------
----------
a=50deg+-5deg b=53deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(10deg)
----------
----------
a=(10deg)
Information:
Start By:a. remove valve covers Call out (1) and (2) are not used in this removal procedure. Call outs begin with number (3). 1. Remove bolts (3) that hold the valve cover bases to the cylinder head assembly. Remove valve cover bases (4).
To prevent damage to the fuel injection nozzle, hold adapter assembly (5) in position at the of injection nozzle (6) when fuel line nut (7) is loosened or tightened.
2. Use Tool (A) and a 7/8 5P0328 Crow Foot ( in) to loosen the fuel injection line nut at the nozzle end. 3. Use Tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (8). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 4. Remove bolts (9) that hold the rocker shaft assemblies to the cylinder head assembly.5. Remove rocker shaft assemblies (10). 6. Put identification marks on the push rods as to their location in the engine. Remove push rods (11). 7. Put identification marks on the bridges as to their location in the engine. Remove bridges (12) from the dowels on the cylinder head assembly.Install Rocker Shaft Assemblies & Push Rods
1. Put clean engine oil on the bridges and dowels. Install the original bridges in their respective locations. New bridges can be mixed.2. Install bridges (1) on the bridge dowels. While firmly pressing 0.5 to 4.5 kg (1 to 10 lb) straight down on the top contact surface of the bridge, turn the adjusting screw clockwise until contact is made with the valve stem. Turn the screw an additional 1/31/2 20 to 30 degrees ( to of 1 hex on nut). This will straighten the dowel in the guide and compensate for the slack in the threads. Hold the adjusting screw in this position and tighten the locknut to a torque of 30 4 N m (22 3 lb ft). Install the original push rods in their respective locations in the engine. New push rods can be mixed.3. Install push rods (2). 4. Put rocker shaft assemblies (3) in position on the cylinder head assembly.5. Put clean engine oil on the threads of the bolts that hold the rocker shaft assemblies in place. Tighten the bolts first to a torque of 270 25 N m (200 18 lb ft). Start with the bolt in the center of the rocker shaft assembly. Tighten the bolts again to a torque of 450 20 N m (330 15 lb ft). Tighten the bolts again by hand to a torque of 450 20 N m (330 15 lb ft).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (4). Tighten the fuel injection line adapter nuts (5) to a torque 40 7 N m (30 5 lb ft) with Tool (A).
Do not let the tops of the fuel nozzles turn when the fuel
To prevent damage to the fuel injection nozzle, hold adapter assembly (5) in position at the of injection nozzle (6) when fuel line nut (7) is loosened or tightened.
2. Use Tool (A) and a 7/8 5P0328 Crow Foot ( in) to loosen the fuel injection line nut at the nozzle end. 3. Use Tool (B) to loosen the nut at the fuel injection line adapter end. Remove inner fuel injection lines (8). Install caps and plugs on all fuel injection line openings to keep dirt out of the fuel system. 4. Remove bolts (9) that hold the rocker shaft assemblies to the cylinder head assembly.5. Remove rocker shaft assemblies (10). 6. Put identification marks on the push rods as to their location in the engine. Remove push rods (11). 7. Put identification marks on the bridges as to their location in the engine. Remove bridges (12) from the dowels on the cylinder head assembly.Install Rocker Shaft Assemblies & Push Rods
1. Put clean engine oil on the bridges and dowels. Install the original bridges in their respective locations. New bridges can be mixed.2. Install bridges (1) on the bridge dowels. While firmly pressing 0.5 to 4.5 kg (1 to 10 lb) straight down on the top contact surface of the bridge, turn the adjusting screw clockwise until contact is made with the valve stem. Turn the screw an additional 1/31/2 20 to 30 degrees ( to of 1 hex on nut). This will straighten the dowel in the guide and compensate for the slack in the threads. Hold the adjusting screw in this position and tighten the locknut to a torque of 30 4 N m (22 3 lb ft). Install the original push rods in their respective locations in the engine. New push rods can be mixed.3. Install push rods (2). 4. Put rocker shaft assemblies (3) in position on the cylinder head assembly.5. Put clean engine oil on the threads of the bolts that hold the rocker shaft assemblies in place. Tighten the bolts first to a torque of 270 25 N m (200 18 lb ft). Start with the bolt in the center of the rocker shaft assembly. Tighten the bolts again to a torque of 450 20 N m (330 15 lb ft). Tighten the bolts again by hand to a torque of 450 20 N m (330 15 lb ft).
Do not cause damage to the O-ring seals on the inner fuel lines.
6. Install inner fuel injection lines (4). Tighten the fuel injection line adapter nuts (5) to a torque 40 7 N m (30 5 lb ft) with Tool (A).
Do not let the tops of the fuel nozzles turn when the fuel