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ZEXEL

COMPONENTS
Date:
Time:
31.08.12
00:43:06
+ INJECTION-PUMP ASSEMBLY 104740-8134 9 460 612 700
Manufacturer No.: MD167343
- FUEL-INJECTION PUMP 104640-8134 9 461 622 223 NP-VE4/10F2100RNP947
-
-
-
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- NOZZLE AND HOLDER ASSY. 105148-1112 9 430 610 407 00121
Nozzle and Holder:
Open Pre:MPa(Kgf/cm2): 11.8{120}
- NOZZLE-HOLDER 105078-0012 9 430 615 121
- NOZZLE 105007-1120 9 432 610 062 NP-DN0PDN112
104740-8134 ZEXEL test values diesel fuel-injection equipment 31.08.12 00:43:27 Page 1
ZEXEL Ass'y No. 104740-8134
Bosch Ass'y No. 9 460 612 700
Bosch Typecode
Engine Type 4D56
Manufacturer MITSUBISHI
Edition date 28.01.02 (1)
1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113orSAEJ967
d
1404 Test oil
P Test oil temperature degC 45 45 50
Nozzle 105780-0060
Bosch type code NP-DN0SD1510
Nozzle holder 105780-2150
P Opening pressure MPa 13 13 13.3
P Opening pressure kgf/cm2 133 133 136
Injection pipe 157805-7320
P Injection pipe mm 2-6-450
Inside diameter - outside diameter - length (mm)
Joint assembly 157641-4720
Tube assembly 157641-4020
P Transfer pump pressure kPa 20 20 20
P Transfer pump pressure kgf/cm2 0.2 0.2 0.2
Direction of rotation (viewed from drive side) R
Right
2 Adjustment specification
2.1 Full load delivery
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 44 42.7 45.3
P Boost pressure mmHg 330 320 340
S Average injection quantity mm3/st. 63.9 63.4 64.4
P Basic *
Remarks
CBS
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2000 2000 2000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
S Average injection quantity mm3/st. 65.1 64.6 65.6
S Difference in delivery mm3/st. 5 5
P Basic *
Remarks
Full
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2650 2650 2650
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Average injection quantity mm3/st. 27.9 24.4 31.4
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2100 2100 2100
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Average injection quantity mm3/st. 64 62.5 65.5
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2000 2000 2000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Average injection quantity mm3/st. 65.1 64.1 66.1
Remarks
Full
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Average injection quantity mm3/st. 70.7 68.2 73.2
C = Check value)
OT = Outside Tolerance (X is set)
104740-8134 ZEXEL test values diesel fuel-injection equipment 31.08.12 00:43:27 Page 2
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 44 42.7 45.3
P Boost pressure mmHg 330 320 340
C Average injection quantity mm3/st. 63.9 62.9 64.9
Remarks
CBS
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 600 600 600
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 48.5 46 51
2.2 Governing
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2650 2650 2650
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
S Average injection quantity mm3/st. 27.9 24.9 30.9
S Difference in delivery mm3/st. 5.5 5.5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2950 2950 2950
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Average injection quantity mm3/st. 5 5
2.3 Idle
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 375 375 375
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
S Average injection quantity mm3/st. 18.4 16.9 19.9
S Difference in delivery mm3/st. 2.5 2.5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 5 5
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 375 375 375
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 18.4 16.4 20.4
2.4 Partial injection quantity
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 35.2 34.2 36.2
2.5 Start
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 100 100 100
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
S Average injection quantity mm3/st. 77 67 87
P Basic *
2.6 Stop
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 375 375 375
P Boost pressure kPa 0 0 0
P Boost pressure mmHg 0 0 0
C Average injection quantity mm3/st. 0 0 0
Remarks
Magnet OFF
2.7 Overflow
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C = Check value)
OT = Outside Tolerance (X is set)
104740-8134 ZEXEL test values diesel fuel-injection equipment 31.08.12 00:43:27 Page 3
C Overflow quantity cm3/min 408 276 540
2.8 Pump chamber pressure
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
S Pressure kPa 411.5 382 441
S Pressure kgf/cm2 4.2 3.9 4.5
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Pressure kPa 411.5 382 441
C Pressure kgf/cm2 4.2 3.9 4.5
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Pressure kPa 529.5 500 559
C Pressure kgf/cm2 5.4 5.1 5.7
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2100 2100 2100
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Pressure kPa 666.5 637 696
C Pressure kgf/cm2 6.8 6.5 7.1
2.9 Timer
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
S Timer stroke mm 3.7 3.5 3.9
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 500 500 500
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Timer stroke mm 1.5 0.7 2.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Timer stroke mm 3.7 3.4 4
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1250 1250 1250
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Timer stroke mm 4.7 4.1 5.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1500 1500 1500
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Timer stroke mm 5.7 5.1 6.3
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2000 2000 2000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Timer stroke mm 7.8 7.2 8.4
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 2100 2100 2100
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Timer stroke mm 7.75 7.3 8.2
2.10 Magnet
CAT Designation Unit Set value min. max. Actual values OT
C Max. applied voltage V 8 8 8
P Test voltage V 13 12 14
C = Check value)
OT = Outside Tolerance (X is set)
104740-8134 ZEXEL test values diesel fuel-injection equipment 31.08.12 00:43:27 Page 4
2.11 Compensator
2.11.1 Load-timer adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
S Average injection quantity mm3/st. 50 49.5 50.5
S Timer stroke variation dT mm 0.7 0.5 0.9
P Basic *
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Average injection quantity mm3/st. 50 49 51
C Timer stroke variation dT mm 0.7 0.3 1.1
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000 1000 1000
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Average injection quantity mm3/st. 40 38.5 41.5
C Timer stroke variation dT mm 1.8 1.2 2.4
2.12 Additional device adjustment
2.12.1 Additional device 1
Name POTENTIOMETER ADJUSTMENT
N1=750r/min
Q1=35.2+-1mm3/st
V1=5+-0.03V
V2=1++V
V3=(8.6)V
Vi=10V
N1=750r/min
Q1=35.2+-1mm3/st
V1=5.0+-0.03V
Adjustment of the potentiometer
Dummy bolt method
1. Hold the dummy bolt against the control lever at position N = N1 and Q = Q1 and fix using the l
ock nut.
2. At potentiometer adjustment, with the control lever contacting the dummy bolt, adjust the poten
tiometer so that the output voltage is V1.
3. After adjustment, remove the dummy bolt and confirm that the potentiometer output voltage at t
he control lever's idling and full speed positions is as specified above.
N:Pump speed
Q:Injection quantity
V:Output voltage
A:Adjusting point
B:Checking point
C:Position of the control lever
C1:Idling
C2:Full speed
Vi:Applied voltage
3 Assembly dimension
CAT Designation Unit Set value min. max. Actual values OT
S K dimension mm 3.3 3.2 3.4
S KF dimension mm 5.8 5.7 5.9
S MS dimension mm 0.7 0.6 0.8
S BCS stroke mm 6.5 6.4 6.6
S Control lever angle alpha deg. 59 55 63
S Control lever angle beta deg. 42 37 47
C = Check value)
OT = Outside Tolerance (X is set)

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