106861-2110 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068612110

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106861-2110 1068612110

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Service parts 106861-2110 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106086-5430

3. GOVERNOR 105487-1560

4. SUPPLY PUMP 105237-1321

5. AUTOM. ADVANCE MECHANIS 105636-1120

6. COUPLING PLATE 105663-0260

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5891

11. Nozzle and Holder ME066565

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-4980

14. NOZZLE 105015-5510

15. NOZZLE SET

Include in #1:

106861-2110 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 106861-2110 1068612110

Zexel num

Bosch num

Firm num

Name

106861-2110
106861-2111

MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9T *

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 131424-4620

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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-7-3- 4-5-6-8

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point -

Rack position 11.4

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 140 135.8 144.2

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 7+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 18.5 16 21

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 140 139 141

Basic *

Fixing the lever *

Boost pressure kPa 40 40

Boost pressure mmHg 300 300

Injection quantity adjustment_04

Adjusting point D

Rack position 11.4+-0. 5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 128.5 124.8 132.2

Fixing the lever *

Boost pressure kPa 18.7 18.7 18.7

Boost pressure mmHg 140 140 140

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 200 200 200

Average injection quantity mm3/st. 130 110 150

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position 9.9

Boost pressure kPa 2.7 2.7 2.7

Boost pressure mmHg 20 20 20

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position (11.4)

Boost pressure kPa 18.7 17.4 20

Boost pressure mmHg 140 130 150

Boost compensator adjustment_03

Pump speed r/min 400 400 400

Rack position (12.5)

Boost pressure kPa 28 28 28

Boost pressure mmHg 210 210 210

Timer adjustment

Pump speed r/min 980--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 930

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Boost compensator cancel stroke: BSL (2)Boost compensator stroke (3)Beginning of damper spring operation: DL
----------
BSL=1.6mm DL=5.8-0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=18deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=34deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Stopper bolt setting (2)Rack position = aa (3)Rack position bb (4)Free (at shipping)
----------
aa=4.7-0.5mm bb=15.3mm
----------
a=43deg+7deg-5deg b=30deg+-5deg c=(10.5deg)

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325+-5r/min Ra=6.7mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)

Information:

1. Drain the cooling system.2. Remove bolt (2) and spacer (1). 3. Remove clip (3) that holds line (4) to the cylinder head. 4. Remove bolts (5) that hold fuel filter base and filter (6) to the cylinder head. 5. Fasten a chain and hoist to the cylinder head lifting brackets. Remove the bolts and nuts that hold the cylinder head. Remove the cylinder head. Weight of the cylinder head is 41 kg (90 lb.). 6. Remove cylinder head gasket (7).7. Check the condition of the cylinder head assembly before installation.Install Cylinder Head Assembly
1. Use a tap of the correct size to clean each threaded hole in the cylinder block for the cylinder head mounting bolts.2. Thoroughly clean the surface for the cylinder head gasket on the cylinder head assembly and cylinder block.
Be sure the gasket is positioned so that all coolant passages in the cylinder block can be seen through the gasket.
3. Put cylinder head gasket (1) in place on the studs in the cylinder block. 4. Put the cylinder head in position on the studs.5. Put clean engine oil on the bolt threads, and install the bolts that hold the cylinder head. 6. Tighten the bolts and nuts in the number sequence shown as follows:a. Tighten all bolts and nuts in number sequence to a torque of 45 N m (35 lb.ft.).b. Tighten all bolts and nuts in number sequence to a torque of 95 N m (70 lb.ft.).c. Again, tighten all bolts and nuts in number sequence to a final torque of 135 N m (100 lb.ft.). Retighten the cylinder head bolts and nuts after the engine has run under part load for approximately thirty minutes.a. If the bolts and nuts move before the correct final torque is reached, retighten every thing in the sequence again to the final torque of 135 N m (100 lb.ft.).b. If the bolts and nuts do not move before the correct final torque is reached, back each one off 30 to 60°, and retighten again, in the sequence shown, to the final torque. After all the bolts and nuts are retightened, check the first 10 positions to make sure they are tightened to the correct torque. 7. Install fuel filter base and filter (2) on the cylinder head with bolts (3).8. Install clip (4) that holds fuel line (5) to the cylinder head.9. Install the alternator bracket bolt and spacer in the cylinder head.End By:a. install fuel injection nozzle assembliesb. install fuel injection linesc. install inlet and exhaust manifoldd. install rocker shaft and push rods