101603-1991 ZEXEL 9 400 615 032 BOSCH INJECTION-PUMP ASSEMBLY 9400615032 1016031991 me035642

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 032 9400615032

ZEXEL 101603-1991 1016031991

MITSUBISHI ME035642 me035642

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Buy INJECTION-PUMP ASSEMBLY 101603-1991 zexel genuine, new aftermarket engine parts with delivery

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Cross reference number

BOSCH 9 400 615 032 9400615032

ZEXEL 101603-1991 1016031991

MITSUBISHI ME035642 me035642

Zexel num

Bosch num

Firm num

Name

101603-1991

9 400 615 032

ME035642 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D14T * 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 131424-5520

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3 2.95 3.05

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 12.1

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 88 85.4 90.6

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 10.5 9 12

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.1)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 88 87 89

Basic *

Fixing the lever *

Boost pressure kPa 61.3 61.3

Boost pressure mmHg 460 460

Injection quantity adjustment_04

Adjusting point C

Rack position (R1-0.8)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 67 65 69

Fixing the lever *

Boost pressure kPa 28 28 28

Boost pressure mmHg 210 210 210

Injection quantity adjustment_05

Adjusting point I

Rack position 13.9+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 90 70 110

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-1.1

Boost pressure kPa 22 22 22

Boost pressure mmHg 165 165 165

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position (R1-0.8)

Boost pressure kPa 28 26.7 29.3

Boost pressure mmHg 210 200 220

Boost compensator adjustment_03

Pump speed r/min 700 700 700

Rack position R1(12.1)

Boost pressure kPa 48 41.3 54.7

Boost pressure mmHg 360 310 410

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B44 BCL=1.1+-0.1mm
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Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C3=(8deg) t1=2--sec. t2=2--sec.
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N1=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=0.5--deg C2=8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=(41deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at speed = rated point and rack position = aa and confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed = bb. Rack position = cc. (3)Rack position = approximately dd (4)Free (at shipping)
----------
aa=7.5mm bb=275r/min cc=(9)mm dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
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N1=400+-5r/min Ra=9.2mm
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0000001601 RACK SENSOR

R:Rack position (mm) V:Voltage (V) After installing the rack sensor, confirm the output value (VR).
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N1=- Ra=R1(12.1)mm VR=1.99+-0.01V
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(1deg)

Information:

B. Back out (loosen) the lift adjustment screw 3/4 1/8of a turn.C. Put the nozzle in a vise with 8S2250 Holding Tool (1). Hold pressure adjusting screw (4) and tighten the locknut to a torque of 8.0-8.5 N m (70-75 lb in) using the 2P5487 Adapter (A). Recheck the opening pressure.Adjustment of 9L7883 Nozzles
1. Remove the nozzle from the tester and place in a vise using 8S2250 Nozzle Holding Tool (1). Loosen lift adjusting screw locknut (2). Loosen lift adjusting screw (3) two full turns counterclockwise.
If lift adjusting screw (3) is not loosened, the valve can be damaged in later steps.
2. Loosen pressure adjusting screw (4) and remove the nozzle from the nozzle holding tool. 3. Tilt the nozzle slightly down from the vertical position and remove pressure screw (4) and shims (5). If the shims do not come out of the nozzle, invert the nozzle and let the shims, spring and spring seat fall into the hand. If the valve comes out of its own weight, handle it carefully by its stem.4. To increase the opening pressure, add a 4N5730 Shim. The 4N5730 Shim is 0.13 mm (.005") thick and will increase the opening pressure approximately 1725 kPa (250 psi). A maximum of two shims can be added; if two shims do not increase opening pressure to specification given, discard the nozzle. 5. Assemble the nozzle, making sure the thickest shim (C) is against pressure screw (4). Put the nozzle in a vise using 8S2250 Nozzle Holding Tool (1). Tighten the pressure adjusting screw to 8.0-9.1 N m (70-80 lb in) torque.6. Remove the nozzle from the holding tool. Connect the nozzle, with the tip facing downward, to the tester. Point the nozzle tip into the 8S2270 Fuel Collector and the FT1384 Extension. Check the opening pressure and if it is not within specifications, repeat steps 4 and 5.Valve Lift Adjustment-9L7883 Nozzles
A. When the correct opening pressure is set, and while pumping test fluid through the nozzle, hold the lift adjusting screw locknut and slowly turn the lift adjusting screw clockwise (CW) until valve pressure rises 1380-3450 kPa (200-500 psi) above the nozzle opening pressure. Some test fluid may collect on the tip, but it must not flow at a rapid dribble.
Do not bend the valve by bottoming with too much force.
B. Back out the lift screw 3/4 1/8 turn, hold the lift adjusting screw, and tighten the locknut just enough so the screw will not turn; the lift is now set. C. Put the nozzle in a vise using 8S2250 Holding Tool (1). Tighten the locknut to 4.0-4.5 N m (35-40 lb in). Recheck valve opening pressure.Adjustment of 9L6969, 7N0449, 9N3299, 9N3700, 9N3979, 1W5829, 4W1819, 4W8483 and 7W3710 Nozzles
1. Put the nozzle in a vise using the 8S2250 Holding Tool (1). Loosen lift adjusting screw locknut (2). Turn lift adjusting screw (3) two full turns counterclockwise (CCW). 2. Hold lift adjusting screw (3) with a .08 mm (5/64") hex wrench (4) and