104745-8473 ZEXEL test values diesel fuel-injection equipment 25/04/24 12:17:45 Page 1

ZEXEL Ass'y No. 104745-8473

Bosch Ass'y No. 9 460 613 400
Bosch Typecode
Engine Type 4D56
Manufacturer MITSUBISHI
Edition date 13/04/12 (5)

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 0 0 0
P Boost pressure mmHg 0 0 0
S Average injection quantity mm3/st. 46.6 46.1 47.1
S Difference in delivery mm3/st. 4 4
P Basic *
P Oil temperature degC 50 48 52
Remarks
NA
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 33.3 32 34.6
P Boost pressure mmHg 250 240 260
S Average injection quantity mm3/st. 53 52.5 53.5
S Difference in delivery mm3/st. 4.5 4.5
P Basic *
P Oil temperature degC 50 48 52
Remarks
CBS
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
S Average injection quantity mm3/st. 65.9 65.4 66.4
S Difference in delivery mm3/st. 5.5 5.5
P Basic *
P Oil temperature degC 50 48 52
Remarks
Full
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. 46.6 45.6 47.6
P Basic *
P Oil temperature degC 50 48 52
Remarks
NA
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 750 750 750
P Boost pressure kPa 33.3 32 34.6
P Boost pressure mmHg 250 240 260

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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C Average injection quantity mm3/st. 53 52 54

P Basic *
P Oil temperature degC 50 48 52
Remarks
CBS
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. 65.7 63.2 68.2
P Oil temperature degC 50 48 52
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. 65.9 64.9 66.9
C Difference in delivery mm3/st. 6 6
P Basic *
P Oil temperature degC 50 48 52
Remarks
Full
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. 53.7 51.2 56.2
P Oil temperature degC 52 50 54
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. 8.5 8.5
P Basic *
P Oil temperature degC 55 52 58
CAT Designation Unit Set value min. max. Actual values OT
P Pump speed r/min 3050 3050 3050
P Boost pressure kPa 73.3 72 74.6
P Boost pressure mmHg 550 540 560
C Average injection quantity mm3/st. 5 5
P Oil temperature degC 55 52 58
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 22.9 32.9
C Difference in delivery mm3/st. 9 9
P Basic *
P Oil temperature degC 55 52 58
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. 16.4 14.9 17.9
S Difference in delivery mm3/st. 2 2
P Basic *
P Oil temperature degC 48 46 50
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. 16.4 14.4 18.4
C Difference in delivery mm3/st. 2.5 2.5
P Basic *
P Oil temperature degC 48 46 50
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
About
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
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P Oil temperature degC 50 48 52

2.4 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. 75 65 85
About
P Basic *
P Oil temperature degC 48 46 50
Remarks
IDLE
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
C Average injection quantity mm3/st. 75 65 85
About
P Oil temperature degC 48 46 50
Remarks
IDLE
2.5 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
P Oil temperature degC 48 46 50
Remarks
Magnet OFF at idling position
2.6 Overflow
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 Overflow quantity cm3/min 420 290 550
P Oil temperature degC 50 48 52
2.7 Pump chamber pressure
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
S Pressure kPa 549 520 578
S Pressure kgf/cm2 5.6 5.3 5.9
P Basic *
P Oil temperature degC 50 48 52
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 Pressure kPa 373 334 412
C Pressure kgf/cm2 3.8 3.4 4.2
P Oil temperature degC 48 46 50
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 Pressure kPa 549 510 588
C Pressure kgf/cm2 5.6 5.2 6
P Basic *
P Oil temperature degC 50 48 52
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 736 697 795
C Pressure kgf/cm2 7.5 7.1 8.1
P Oil temperature degC 52 50 54
2.8 Timer
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
S = Setting value, C = Check value)
OT = Outside Tolerance (X is set)
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S Timer stroke mm 4.6 4.4 4.8

P Basic *
P Oil temperature degC 50 48 52
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 1.2 0.6 1.8
P Oil temperature degC 48 46 50
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 3.5 2.9 4.1
P Oil temperature degC 50 48 52
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 4.6 4.2 5
P Basic *
P Oil temperature degC 50 48 52
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 5.6 5 6.2
P Oil temperature degC 50 48 52
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 7.8 7.2 8.4
P Oil temperature degC 52 50 54
2.9 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
2.10 Compensator
2.10.1 Load-timer adjustment
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
S Average injection quantity mm3/st. 56.9 56.4 57.4
S Timer stroke TA mm 3.9 3.7 4.1
S Timer stroke variation dT mm 0.7 0.7 0.7
About
P Basic *
P Oil temperature degC 50 48 52
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. 56.9 55.9 57.9
C Timer stroke TA mm 3.9 3.5 4.3
C Timer stroke variation dT mm 0.7 0.7 0.7
About
P Basic *
P Oil temperature degC 50 48 52
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. 43 42 44
C Timer stroke TA mm 2.5 1.9 3.1
C Timer stroke variation dT mm 2.1 2.1 2.1
About
P Oil temperature degC 50 48 52

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)
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2.10.2 BCS adjustment

Name BOOST COMPENSATOR ADJUSTMENT
SW=10mm
T=6~9N-m(0.6~0.9kgf-m)

N1=750r/min BCS adjustment procedure

N2=750r/min 1. At full boost pressure, set so that the full injection quantity is within the specifications (adjusting
P1=33.3kPa(250mmHg) point).
P2=0kPa(0mmHg) 2. Perform boost compensator intermediate operation point adjustment (pump speed N1, boost pr
T=6~9N-m(0.6~0.9kgf-m) essure P1).
3. When injection quantity at boost pressure P2 and pump speed N2 is not as specified, loosen n
ut (A) and adjust position of screw (B) so that injection quantity is as specified. The screw position
should be within +-1 turn of initial position.
4. The nut tightening torque is T.

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 1.4 1.3 1.5
S BCS stroke mm 4.7 4.5 4.9
S Control lever angle alpha deg. 59 55 63
S Control lever angle beta deg. 41 36 46

S = Setting value, C = Check value)

OT = Outside Tolerance (X is set)