101401-1722 ZEXEL 9 400 613 638 BOSCH INJECTION-PUMP ASSEMBLY 9400613638 1014011722 me080977

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 638 9400613638

ZEXEL 101401-1722 1014011722

MITSUBISHI ME080977 me080977

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106873-3402 as _

Cross reference number

BOSCH 9 400 613 638 9400613638

ZEXEL 101401-1722 1014011722

MITSUBISHI ME080977 me080977

Zexel num

Bosch num

Firm num

Name

101401-1722

9 400 613 638

ME080977 MITSUBISHI

INJECTION-PUMP ASSEMBLY
4D34T K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

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

Opening pressure MPa 17.2

Opening pressure kgf/cm2 175

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-4620

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

Tester oil delivery pressure kPa 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.5 3.45 3.55

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 11

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 87.5 86.5 88.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.9+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 65 70

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Load 4/4

Remarks
Beginning of advance.

Timer adjustment_02

Pump speed r/min 350

Advance angle deg. 2.5 2 3

Load 0/4

Remarks
Start

Timer adjustment_03

Pump speed r/min (500)

Advance angle deg. 0 0 0

Load 0/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 0.5

Load 4/4

Timer adjustment_05

Pump speed r/min 1400

Advance angle deg. 1.5 1 2

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=8
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=7deg+-5deg b=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring
----------

----------
a=18.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(130deg)

Information:

(1) Crossbar (from 8B7548 Puller).(2) Spacer plate.(3) S1589 Bolt with two 1S379 Washers.(4) 1D4595 Bolt.(5) 3H465 Plate.(6) 1P2403 Dial Indicator.(7) 1P2394 Adapter Plate.(8) 1P2402 Gauge Body.Make reference to Cylinder Liner Projection in Testing and Adjusting for the complete procedure.1. Install gasket and spacer plate (2) with bolts (3) and two 1S379 Washers. Tighten bolts (3) evenly in four steps: 1st step ... 14 N m (10 lb ft)2nd step ... 35 N m (25 lb ft)3rd step ... 70 N m (50 lb ft)4th step ... 95 N m (70 lb ft)2. Install tools as shown. Tighten bolts (4) evenly in four steps: 1st step ... 7 N m (5 lb ft)2nd step ... 20 N m (15 lb ft)3rd step ... 35 N m (25 lb ft)4th step ... 70 N m (50 lb ft)3. Measure cylinder liner projection with dial indicator (6) in 1P2402 Gauge Body (8) as shown. Measure at four places around each cylinder liner near the clamped area. Cylinder liner projection measurements for any cylinder liner must be ... 0.033 to 0.175 mm (.0013 to .0069 in.)Maximum permissible difference between all four measurements ... 0.05 mm (.002 in.)Maximum permissible difference between average projection of any two cylinder liners next to each other ... 0.05 mm (.002 in.)Maximum permissible difference between average projection of all cylinder liners under one cylinder head ... 0.10 mm (.004 in.) If liner projection is not correct, turn the liner to a new position within the bore. If projection can not be corrected this way, move the liner to a different bore. If the projection can not be corrected this way, make reference to Special Instruction, Form No. FMO55228 for complete instructions on the use of 8S3140 Counterboring Tool Arrangement. 4. Minimum permissible depth to machine counterbore to adjust cylinder liner projection ... 0.76 mm (.030 in.) Maximum permissible depth to machine counterbore to adjust cylinder liner protection ... 1.14 mm (.045 in.)Install a 0.76 mm (.030 in.) shim plus any added shims necessary to get the correct cylinder liner projection. Be sure that the 0.76 mm (.030 in.) shim is directly under the cylinder liner flange.