106871-7560 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068717560 me090613

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106871-7560 1068717560

MITSUBISHI ME090613 me090613

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Cross reference number

ZEXEL 106871-7560 1068717560

MITSUBISHI ME090613 me090613

Zexel num

Bosch num

Firm num

Name

106871-7560
106871-7700

ME090613 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9 * K

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 132424-0620

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

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 9.5

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 118 114.5 121.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.5)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 118 117 119

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 124 118.8 129.2

Difference in delivery mm3/st. 10.4 10.4 10.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 135 175

Fixing the lever *

Remarks
After startup boost setting

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Damper spring setting: DL
----------
SXL=10.4+-0.1mm DL=4.3-0.2mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
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N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

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

----------
a=21deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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----------
a=10deg+-5deg b=26deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Rack position bb (4)Free (at shipping)
----------
aa=4-0.5mm bb=11.7mm
----------
a=43deg+7deg-5deg b=21.5deg+-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=5.6mm
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0000001601 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
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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:

start by:a) remove turbocharger 1. Put the turbocharger in position on tool (A). Move tool (A) so the compressor housing is up. 2. For installation alignment purposes, make a mark on the center housing and turbine housing. Bend down the lock plates and remove six bolts (1). If some of the bolts are hard to remove, put penetrating oil on the bolt and hit the flat of the bolt head with a punch and hammer. 3. Lift the center housing and turbine wheel out of the turbine housing. If the assembly is hard to get apart, lift up on the compressor housing and hit the turbine housing with a soft hammer. 4. Remove clamp (2) from the compressor housing. For installation alignment purposes, make a mark on the center housing and the compressor housing. 5. Lift the center housing out of the compressor housing. Put the turbine wheel in tooling (B).6. Remove nut (3) with a universal socket. Remove O-ring (4).
Do not put a side force on the shaft when the nut is removed.
7. Heat the compressor wheel in oil for no more than ten minutes. The temperature of the oil must be 350° 25°F (176° 14°C).
The bearing heating oil used to heat the compressor wheel must have a flash point above 400°F (204°C).
8. Immediately after removing the compressor wheel from the oil, put the center housing in a press and use tooling (C) and (D) to remove the compressor wheel and center housing from the shaft.
Do not let the turbine wheel hit the bottom of the press.
9. Put the turbine wheel in tooling (B) and remove ring (6) and shroud (5). 10. Remove three bolts (7) and the three lock plates from center housing (8). 11. Remove plate (9) with tool (E). Remove the O-ring from plate (9). 12. Remove spacer (10) from plate (9). Remove collar (11) and thrust bearing (15). Remove bearing (12) and put a long dye mark on the top face of the bearing. Use tool (F) to remove rings (16) and (13). Remove bearing (17) and put a short dye mark on the top face of the bearing. Remove ring (14) with tool (F). The dye marks are for identification when installing the bearings.13. Inspect all parts and install new parts if needed. Use Special Instruction Form No. GMG00153-01, Turbocharger Reconditioning, Form No. FEG45138, Analyzing Turbocharger Failure and Video Tape JEG08054 (1/2 inch reel) (JEG09052-cassette), Turbocharger Reconditioning I (AIRESEARCH) for references.Assemble Turbocharger
1. Make sure all oil passages are open and clean. Put clean engine oil on all parts before assembly. 2. Install ring (3) with tool (A). Install bearing (4) with the short dye mark up. Install rings (2) and (1) with tool (A). Rings (1), (2) and (3) must be installed with the round edge toward the bearing. 3. Install shroud (5) on the turbine shaft. Install ring (6). Put 6V2055 High Vacuum Grease on ring (6) and fill the groove for the ring to one half depth all