101606-6240 ZEXEL test values diesel fuel-injection equipment 29/11/09 15:31:17 Page 1

ZEXEL Ass'y No. 101606-6240

Bosch Ass'y No. 9 400 615 499
Bosch Typecode
Engine Type 6D22
Manufacturer MITSUBISHI
Edition date 08/08/03

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 131424-5120
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 157 157 157
P Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6
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 1-5-3-6-2-4
S Pre-stroke mm 4.5 4.45 4.55
P Beginning of injection position NO.1
Governor side
S Difference between angles 1 deg. 60 59.5 60.5
Cal 1-5
S Difference between angles 2 deg. 120 119.5 120.5
Cal 1-3
S Difference between angles 3 deg. 180 179.5 180.5
Cal 1-6
S Difference between angles 4 deg. 240 239.5 240.5
Cyl.1-2
S Difference between angles 5 deg. 300 299.5 300.5
Cal 1-4
2.2 Injection quantity adjustment
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point -
P Rack position 9.6
P Pump speed r/min 700 700 700
S Each cylinder's injection qty mm3/st. 112 108.6 115.4
P Basic *
P Fixing the rack *
P Standard for adjustment of the maximum vari *
ation between cylinders
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point C
P Rack position 8+-0.5
P Pump speed r/min 225 225 225
S Each cylinder's injection qty mm3/st. 18.5 15.7 21.3
P Fixing the rack *
P Standard for adjustment of the maximum vari *
ation between cylinders
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point A

OT = Outside Tolerance (X is set)

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P Rack position R1(9.6)

P Pump speed r/min 700 700 700
S Average injection quantity mm3/st. 112 111 113
P Basic *
P Fixing the lever *
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point B
P Rack position R1(9.6)
P Pump speed r/min 1100 1100 1100
S Average injection quantity mm3/st. 113.5 111 116
S Difference in delivery mm3/st. 9 9 9
P Fixing the lever *
CAT Designation Unit Set value min. max. Actual values OT
P Adjusting point E
P Rack position -
P Pump speed r/min 100 100 100
S Average injection quantity mm3/st. 140 120 160
P Fixing the lever *
Remarks
After startup boost setting
2.3 Governor adjustment
Name

RT=1 N:Pump speed

TH=2.9mm R:Rack position (mm)
SXL=R1+0.2mm (1)Lever ratio: RT
DL=6.8-0.2mm (2)Target shim dimension: TH
(3)Excess fuel setting for starting: SXL
(4)Damper spring setting: DL
2.4 Timer adjustment
CAT Designation Unit Set value min. max. Actual values OT
S Pump speed r/min 850--
P Advance angle deg. 0 0 0
Remarks
Start
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 800
S Advance angle deg. 0.5 0.5
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1000

OT = Outside Tolerance (X is set)

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S Advance angle deg. 0.9 0.4 1.4

CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 1150
S Advance angle deg. 3 2.5 3.5
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min -
S Advance angle deg. 4 4 5
Remarks
Measure the actual speed, stop
2.5 Speed control lever angle
Name
a=10deg+-5deg

F:Full speed
2.6 Load control lever angle
Name
a=21deg+-5deg
b=29deg+-3deg

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

OT = Outside Tolerance (X is set)

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2.7 Stop lever angle

Name
a=(58deg)
b=36deg+5deg-7deg
c=24deg+-5deg

aa=13.5mm N:Pump normal

bb=6-0.5mm S:Stop the pump.
(1)Free (at shipping)
(2)Rack position = aa
(3)Rack position = bb, set the stopper bolt.
2.8 Additional device adjustment
2.8.1 Additional device 1
Name MICRO SWITCH

N1=325+-5r/min Adjustment of the micro-switch

Ra=7.3mm Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
2.9 Timing setting
Name
a=(7deg)

(1)Pump vertical direction

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

OT = Outside Tolerance (X is set)