101609-9191 ZEXEL 9 400 615 920 BOSCH INJECTION-PUMP ASSEMBLY 9400615920 1016099191 3436501031

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 920 9400615920

ZEXEL 101609-9191 1016099191

MITSUBISHI-HEAV 3436501031 3436501031

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104015-8190 as _

Cross reference number

BOSCH 9 400 615 920 9400615920

ZEXEL 101609-9191 1016099191

MITSUBISHI-HEAV 3436501031 3436501031

Zexel num

Bosch num

Firm num

Name

101609-9191
101609-9192

9 400 615 920

3436501031 MITSUBISHI-HEAV

INJECTION-PUMP ASSEMBLY
S6K * K 14BE PE6A PE

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 131424-5720

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

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

Pre-stroke mm 3.7 3.65 3.75

Rack position
After adjusting injection quantity. R=A

Beginning of injection position
Drive 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 A

Rack position 8.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 72 71 73

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 85.3 85.3

Boost pressure mmHg 640 640

Injection quantity adjustment_02

Adjusting point -

Rack position 7.2+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 12 10.7 13.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position 8.95

Boost pressure kPa 33.3 30.6 36

Boost pressure mmHg 250 230 270

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position 9.6

Boost pressure kPa 72 72 72

Boost pressure mmHg 540 540 540

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)Boost compensator stroke (4)Rack difference between N = N1 and N = N2
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K=14 N1=1100r/min N2=700r/min
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=70mm
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a=15deg+-5deg b=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Speed = bb, rack position = cc (sealed at delivery) (3)Normal
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aa=25mm bb=0r/min cc=1-0.5mm
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a=21deg+-5deg b=(55deg)

0000001501 I/P WITH LOAD PLUNGER ADJ

Load plunger-equipped pump adjustment 1. Adjust the variation between cylinders and the injection quantity. 2. At Full point A, adjust the pre-stroke to the specified value. 3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
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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)After adjusting the injection quantity, adjust at rack position bb.
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aa=6deg bb=8.6mm
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a=(110deg)

Information:

start by:a) remove fuel injection pump housing and governor 1. Install the fuel injection pump housing on tool (A).2. Remove the bolts (1) that hold the governor housing (2) to the fuel injection pump housing.3. Remove the governor housing (2). 4. Remove two springs (4) and the seat (5) from the governor housing.5. Remove the seat (7) from the shaft.6. Remove the spring (6) from the shaft.7. Remove the cover (3) from the pump housing. 8. Remove the shaft (8) and the lever (9) from the pump housing. 9. Remove the thrust collar (11) from the shaft.10. Remove the cover (10) from the pump housing. 11. Loosen the two bolts (13) that hold the torque spring assembly (12) and remove it from the pump housing. 12. Remove the pin (15) from the pump housing.13. Remove the screw (14) and the nut (16) from the pump housing.14. Remove the ring that holds the lever and remove the lever (18) from the dowel (17).15. Remove the dowel (17) from the pump housing. Dowel does not need to be removed unless camshaft is to be removed.
Pull on the shield only a small amount in each location so it will not have distortion or damage. A damaged shield must be replaced.
16. Remove the shield (19) from the camshaft with tool (B). 17. Install the timing pin (C) to hold the camshaft.18. Remove the bolts (20) that hold the flyweight assembly to the camshaft. 19. Remove the flyweight assembly (21) from the camshaft.20. Remove the timing pin (C) from the pump housing.Connection Of Governor To Fuel Injection Pump Housing
1. Put the fuel injection pump housing on the bracket assembly (A).2. Install the timing pin (B) to hold the camshaft.3. Put the flyweight assembly (1) in position on the camshaft. Be sure the pin that holds the shaft (2) is in position on the back of the flyweight assembly.4. Install the bolts that hold the flyweight assembly to the camshaft and tighten to a torque of 10 2 lb. ft. (1.38 0.28 mkg).5. Remove the timing pin (B). 6. Put the shield (3) in position over the flyweights. 7. Use the driver (C) to install the shield the remainder of the way on to the camshaft. 8. Put a new O-ring seal on the dowel (4) and install the dowel in the pump housing. Make the dowel even with the machined surface of the counterbore on the outside of the housing. 9. Put the lever (8) on the dowel (4) and install the ring that holds it on the dowel.10. Install the screw (6) and the nut (7) in the pump housing.11. Install the pin (5) in the pump housing. 12. Put the torque spring assembly (10) in position on the housing and tighten the two bolts (11) that hold it to the housing.13. Install the cover (9) on the pump housing. 14. Put the thrust collar (13) in position between the flyweights. Lift the flyweights up with a piece of wire