101405-9342 ZEXEL test values diesel fuel-injection equipment 03-05-22 02:30:36 Page 1

ZEXEL Ass'y No. 101405-9342

Bosch Ass'y No. 9 400 612 993
Bosch Typecode
Engine Type S4K-T
Manufacturer MITSUBISHI HEAV
Edition date 13-01-05 (8)

1 Adjustment conditions
CAT Designation Unit Set value min. max. Actual values OT
Test oil ISO4113 or {SAEJ96
7d}
1404 Test oil
P 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
P Opening pressure MPa 17.2
P Opening pressure kgf/cm2 175
Injection pipe mm 6-2-600
Outer diameter - inner diameter - length (mm)
Overflow valve 131424-5720
P Overflow valve opening pressure kPa 255 221 289
P Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95
P Tester oil delivery pressure kPa 255 255 255
P Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6
Direction of rotation (viewed from drive side) R
Right

2 Adjustment specification
2.1 Injection timing adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Direction of rotation (viewed from drive side) R
Right
P Injection order 1-3-4-2
S Pre-stroke mm 3.5 3.45 3.55
S Rack position R=A
After adjusting injection quantity.
P Beginning of injection position NO.1
Drive side
S Difference between angles 1 deg. 90 89.5 90.5
Cal 1-3
S Difference between angles 2 deg. 180 179.5 180.5
Cal 1-4
S Difference between angles 3 deg. 270 269.5 270.5
Cyl.1-2
2.2 Injection quantity adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point A
P Rack position 9.1
P Pump speed r/min 975 975 975
S Average injection quantity mm3/st. 93.5 92.5 94.5
S Max. variation between cylinders % 0 -2.5 2.5
P Basic *
P Fixing the lever *
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point D
P Rack position 6.8+-0.5
P Pump speed r/min 400 400 400
S Average injection quantity mm3/st. 12 10.7 13.3
S Max. variation between cylinders % 0 -10 10
P Fixing the rack *
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point E
P Rack position 9.3++
P Pump speed r/min 100 100 100
S Average injection quantity mm3/st. 80 80 85
P Fixing the lever *
P Rack limit *

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.3 Governor adjustment

Name

K=10 N:Pump speed

N1=975r/min R:Rack position (mm)
N2=400r/min (1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Rack difference between N = N1 and N = N2
2.4 Speed control lever angle
Name
a=17deg+-5deg
b=0deg+-5deg
c=31deg+-3deg

F:Full speed
I:Idle
S:Stop

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.5 Stop lever angle

Name
a=21deg+-5deg
b=(55deg)

aa=25mm N:Pump normal

bb=0r/min S:Stop the pump.
cc=1-0.5mm (1)Use the hole at R = aa
(2)Speed = bb, rack position = cc (sealed at delivery)
(3)Normal
2.6 Additional device adjustment
2.6.1 Additional device 1
Name I/P WITH LOAD PLUNGER ADJ

Load plunger-equipped pump adjustment

1. Adjust the variation between cylinders and the injection quantity.
2. At Full point A, adjust the pre-stroke to the specified value.
3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between
cylinders is as specified.
2.7 Timing setting
Name
a=(110deg)

aa=6deg (1)Pump vertical direction

bb=9.1mm (2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)After adjusting the injection quantity, adjust at rack position bb.

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)