101891-6510 ZEXEL 9 400 616 220 BOSCH INJECTION-PUMP ASSEMBLY 9400616220 1018916510 3126185021

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 220 9400616220

ZEXEL 101891-6510 1018916510

MITSUBISHI 3126185021 3126185021

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Service parts 101891-6510 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101089-0470

3. GOVERNOR 105412-1450

4. SUPPLY PUMP 105210-4220

5. AUTOM. ADVANCE MECHANIS 105612-3010

6. COUPLING PLATE 105662-0510

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105151-1330

11. Nozzle and Holder 31161-18000

12. Open Pre:MPa(Kqf/cm2) 11.8{120}

13. NOZZLE-HOLDER 105081-2140

14. NOZZLE

105000-1130

15. NOZZLE SET

Include in #1:

101606-1991 as _

101891-6510 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 220 9400616220

ZEXEL 101891-6510 1018916510

MITSUBISHI 3126185021 3126185021

Zexel num

Bosch num

Firm num

Name

101891-6510

9 400 616 220

3126185021 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC20 K 14BG INJECTION PUMP ASSY PE8A 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

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 1-2-7-3- 4-5-6-8

Pre-stroke mm 2.2 2.15 2.25

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

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

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 14

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 138 133.9 142.1

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 12.3

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 121.8 117 126.6

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 5.5+-0.5

Pump speed r/min 200 200 200

Average injection quantity mm3/st. 12.4 9.8 15

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 250+120

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 1.4 0.8 2

Timer adjustment_03

Pump speed r/min 800

Advance angle deg. 4.2 3.6 4.8

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 8 7.3 8.5

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 10 10 10

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: RAL (3)Set the torque control spring so that the injection quantity passes through point B. (4)Torque spring does not operate.
----------
K=8 RAL=14.5+0.5mm
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=(14deg) b=32deg+-3deg c=(19deg)

Information:

Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Table 1
Required Parts
Qty Part Number Part Name
1 420-0939 Sleeve(1)
1 420-0940 Sleeve(2)
1 420-0941 Sleeve(3)
1 420-0942 Sleeve(4)
(1) Red
(2) Silver
(3) Gold
(4) GreenSleeve Rework procedure
Illustration 1 g06360367
Typical example of an injector - without sleeve
(A) Adjustment screw
(B) Locknut
Remove and retain adjustment screw (A). Remove and discard locknut (B).
Illustration 2 g06360368
Typical example of an injector - with sleeve
(1) Sleeve
(A) Adjustment screw
Insert appropriate sleeve (1) onto adjustment screw (A).