101691-1991 ZEXEL 9 400 615 981 BOSCH INJECTION-PUMP ASSEMBLY 9400615981 1016911991 me088110

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 981 9400615981

ZEXEL 101691-1991 1016911991

MITSUBISHI ME088110 me088110

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Include in #2:

104745-3820 as _

104745-3821

Cross reference number

BOSCH 9 400 615 981 9400615981

ZEXEL 101691-1991 1016911991

MITSUBISHI ME088110 me088110

Zexel num

Bosch num

Firm num

Name

101691-1991

9 400 615 981

ME088110 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D31 * 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 131424-5620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-5-3-6- 2-4

Pre-stroke mm 3.5 3.45 3.55

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 9.6

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 50.3 49.3 51.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.4+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 7.5 6.2 8.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

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

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 67.5 67.5 72.5

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 750

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 750.

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 3 3 3

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Idle sub spring setting: L1. (4)At shipping (5)Rack difference between N = N1 and N = N2
----------
K=15 L1=6.3+-0.1mm N1=750r/min N2=400r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa (2)At shipping (3)Set the pump speed at bb. (4)Stopper bolt setting
----------
aa=750r/min bb=900r/min
----------
a=26deg+-5deg b=3deg+-5deg c=(2deg) d=7deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At shipping
----------

----------
a=38deg+-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=20deg
----------
a=(140deg)

Information:

start by:a) remove fuel injection pump housing and governor1. Install the fuel injection pump housing on tool (A). 2. Remove seven bolts (1) and governor housing (2). Later fuel injection pump housings have a thrust washer for the fuel injection pump camshaft. The thrust washer is behind the flange for the flyweights on the camshaft. To hold the thrust washer in place governor shaft (3) and the camshaft must be held in toward the fuel transfer pump any time sleeve (4) is removed. 3. Remove the plug from the cover and install tool (B) in the hole as shown. Turn the injection pump camshaft until tool (B) can be pushed into the groove (slot) in the camshaft. Any time the drive sleeve is removed from the camshaft a new one must be installed. The camshaft has serrations (splines) that cut grooves into the drive sleeve when it is installed to give a positive drive connection. If a formerly used drive sleeve is installed again it can slip (slide around) on the camshaft. 4. Install tool (C) in the threads of sleeve (4). Tighten the bolt until the sleeve can be removed. 5. Remove four bolts (5) and fuel transfer pump body (6) from the housing.6. Disconnect drain line (7) from the fitting on the back of fuel transfer pump body. 7. Remove gear (8) and O-ring seal (9) from the pump body. 8. Remove seals (10) from the pump body. 9. Remove drive gear (11) and the key from the camshaft. Install Fuel Transfer Pump
The fuel injection camshaft must be held in toward the fuel transfer pump during installation of the fuel transfer pump parts to hold the camshaft thrust washer in its counterbore. The thrust washer will be damaged when the sleeve is installed on the camshaft if it is not in the correct position. 1. Install key (1) and drive gear (2) on the shaft.2. Put No. 3 Aviation Permatex on the outside diameter of the seals for body (3). 3. Use tooling (B) to install the first seal in the body with the lip down and the second seal with the lip up. Install the first seal to a depth of 11.5 mm (.453 in.) and the second seal to a depth of 0.75 mm (.030 in.).4. Remove the extra permatex from the body and seals after installation. Be sure the drain hole between the seals is open. 5. Install O-ring seal (4) and gear (5) on the body. 6. Install tool (C) in the end of the fuel injection pump camshaft. Connect drain line (6) to the fitting on the back of the body and put the body in position on the fuel injection pump housing. Install the bolts that hold the body in place.7. Install tool (E) in the camshaft so it will not turn.8. Put a new sleeve (7) on the camshaft. A new drive sleeve must be installed because a used drive sleeve can slip (slide around) on the camshaft.9. Tighten