104741-3020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1047413020 me200201

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 104741-3020 1047413020

MITSUBISHI ME200201 me200201

Cross reference number

ZEXEL 104741-3020 1047413020

MITSUBISHI ME200201 me200201

Zexel num

Bosch num

Firm num

Name

104741-3020
104741-3021

ME200201 MITSUBISHI

INJECTION-PUMP ASSEMBLY
E65X TC * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

Transfer pump pressure kPa 20 20 20

Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side)
Right R

(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF. OFF

Injection timing adjustment

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 53.5 53 54

Difference in delivery mm3/st. 4

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_02

Pump speed r/min 600 600 600

Boost pressure kPa 31.3 30 32.6

Boost pressure mmHg 235 225 245

Average injection quantity mm3/st. 68.2 67.7 68.7

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 75.6 75.1 76.1

Difference in delivery mm3/st. 6

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_04

Pump speed r/min 550 550 550

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 53.5 52.5 54.5

Basic *

Oil temperature degC 50 48 52

Remarks
NA

Injection timing adjustment_05

Pump speed r/min 600 600 600

Boost pressure kPa 31.3 30 32.6

Boost pressure mmHg 235 225 245

Average injection quantity mm3/st. 68.2 67.2 69.2

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_06

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 75.6 74.6 76.6

Difference in delivery mm3/st. 6.5

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_07

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 71.4 67.4 75.4

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 2475 2475 2475

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 33 30 36

Difference in delivery mm3/st. 5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_02

Pump speed r/min 2475 2475 2475

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 33 28 38

Difference in delivery mm3/st. 5.5

Basic *

Oil temperature degC 55 52 58

Injection quantity adjustment_03

Pump speed r/min 2800 2800 2800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Average injection quantity mm3/st. 8

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 365 365 365

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.5 8.5 12.5

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 365 365 365

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 10.5 8 13

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 48 46 50

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 50 40 60

Basic *

Oil temperature degC 48 46 50

Remarks
IDLE

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 50 40 60

Basic *

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 365 365 365

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

0000000901

Pump speed r/min 1100 1100 1100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Overflow quantity with S/T ON cm3/min 850 720 980

Overflow quantity with S/T OFF cm3/min 930 800 1060

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T ON kPa 559 520 598

Pressure with S/T ON kgf/cm2 5.7 5.3 6.1

Pressure with S/T OFF kPa 481 461 501

Pressure with S/T OFF kgf/cm2 4.9 4.7 5.1

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 700 700 700

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T ON kPa 422 373 471

Pressure with S/T ON kgf/cm2 4.3 3.8 4.8

Pressure with S/T OFF kPa 284 235 333

Pressure with S/T OFF kgf/cm2 2.9 2.4 3.4

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 800 800 800

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T OFF kPa 353 304 402

Pressure with S/T OFF kgf/cm2 3.6 3.1 4.1

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 900 900 900

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T OFF kPa 392 353 431

Pressure with S/T OFF kgf/cm2 4 3.6 4.4

Oil temperature degC 50 48 52

Stop lever angle_05

Pump speed r/min 1000 1000 1000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T OFF kPa 422 383 461

Pressure with S/T OFF kgf/cm2 4.3 3.9 4.7

Oil temperature degC 50 48 52

Stop lever angle_06

Pump speed r/min 1100 1100 1100

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T ON kPa 530 481 579

Pressure with S/T ON kgf/cm2 5.4 4.9 5.9

Pressure with S/T OFF kPa 451 412 490

Pressure with S/T OFF kgf/cm2 4.6 4.2 5

Oil temperature degC 50 48 52

Stop lever angle_07

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T ON kPa 559 510 608

Pressure with S/T ON kgf/cm2 5.7 5.2 6.2

Pressure with S/T OFF kPa 481 452 510

Pressure with S/T OFF kgf/cm2 4.9 4.6 5.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_08

Pump speed r/min 2000 2000 2000

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Pressure with S/T ON kPa 696 647 745

Pressure with S/T ON kgf/cm2 7.1 6.6 7.6

Pressure with S/T OFF kPa 628 589 667

Pressure with S/T OFF kgf/cm2 6.4 6 6.8

Oil temperature degC 50 48 52

0000001101

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 6.7 6.2 7.2

Timer stroke with S/T OFF mm 4.7 4.5 4.9

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 700 700 700

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 3.3 2.6 4

Timer stroke with S/T OFF mm 0.8

Oil temperature degC 50 48 52

_03

Pump speed r/min 1250 1250 1250

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T ON mm 6.7 6 7.4

Timer stroke with S/T OFF mm 4.7 4.3 5.1

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 73.3 72 74.6

Boost pressure mmHg 550 540 560

Timer stroke with S/T OFF mm 9.8 9.3 10.2

Oil temperature degC 52 50 54

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.01 5.91 6.11

MS dimension mm 0.7 0.6 0.8

BCS stroke mm 4.5 4.3 4.7

Control lever angle alpha deg. 59 55 63

Control lever angle beta deg. 42 37 47

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Adjustment of the potentiometer Vi:Applied voltage C:Position of the control lever N:Pump speed V:Output voltage Q:Injection quantity A:Adjusting point C1:Idling C2:Full speed
----------

----------
V1=1.6+-0.03(V) V2=(8.6(V)) Vi=10(V)

0000001901 V-FICD ADJUSTMENT

Adjustment of the two stage actuator (FICD). 1. Install the 2-stage actuator on the injection pump. 2. With the control lever in the idle position adjust using the rod position adjusting nut so that the clearance between control lever and the rod is L1. 3. The actuator stroke is adjusted on the engine. 4. Rod position's allowable angle of rotation: c (C) Rod position adjusting nut (D) Stroke adjusting nut (E) Actuator stroke
----------
L1=1+1(mm) c=+-20(deg)
----------
L1=1+1(mm) SW1=SW7 SW2=SW8 T1=1.4~2.0(Nm)(0.14~0.2(kgfm)) T2=3.4~4.9(Nm)(0.35~0.5(kgfm)) a=20(deg) b=20(deg)

0000002001 W-FICD LEVER ADJUSTMENT

2. Adjustment of the W-FICD (1)Insert a block gauge L determined from the graph between the control lever (B) and the idling set screw (A). (2)Fix bolt (E) in the position where W-FICD lever (C) contacts the control lever (D). (Tighten to torque T.) (3)Remove the block gauge and shims after completing adjustment. Caution: The temperature of the wax at adjustment must not exceed a. G = control lever L dimension (control lever position) H = temperature t (deg C)
----------
L=L+-0.3mm T=3.4~4.9N-m(0.35~0.5kgf-m) a=35degC
----------
L=-0.115t+4.6(0<=t(degC))