101401-1150 ZEXEL 9 400 610 057 BOSCH INJECTION-PUMP ASSEMBLY 9400610057 1014011150

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 057 9400610057

ZEXEL 101401-1150 1014011150

Service parts 101401-1150 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9320

3. GOVERNOR

4. SUPPLY PUMP 105220-5150

5. AUTOM. ADVANCE MECHANIS 105676-0250

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4120

11. Nozzle and Holder ME017801

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3070

14. NOZZLE

105017-0100

15. NOZZLE SET

Include in #1:

101401-1150 as INJECTION-PUMP ASSEMBLY

101501-2000 as _

Cross reference number

BOSCH 9 400 610 057 9400610057

ZEXEL 101401-1150 1014011150

Zexel num

Bosch num

Firm num

Name

101401-1150
101401-1152

9 400 610 057

MITSUBISHI

INJECTION-PUMP ASSEMBLY
4D31T *

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 131424-6220

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 3.6 3.55 3.65

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 -

Rack position 10.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 55.1 54.1 56.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 10 8.7 11.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.6)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 55.1 54.1 56.1

Basic *

Fixing the lever *

Boost pressure kPa 42.7 42.7

Boost pressure mmHg 320 320

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.3

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 71 67 75

Fixing the lever *

Boost pressure kPa 42.7 42.7

Boost pressure mmHg 320 320

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 39.9 35.9 43.9

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point D

Rack position R2+0.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 35.7 31.7 39.7

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 67 67 72

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-0.4

Boost pressure kPa 22.7 21.4 24

Boost pressure mmHg 170 160 180

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(10.6)

Boost pressure kPa 36 29.3 36

Boost pressure mmHg 270 220 270

Timer adjustment

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min 1700

Advance angle deg. 3.5 3 4

Remarks
Finish

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=B88 BCL=0.4+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=42deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Free (at shipping) (2)Use the hole at R = aa (3)Rack position corresponding to bb (4)Set the stopper bolt so that speed = cc and rack position = dd. (5)After setting the stopper bolt, confirm non-injection at speed ee. (Rack position = ff or less)
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=325r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-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
----------
N1=950+-5r/min Ra=8mm
----------

0000001601 ACTUATOR

(a) Screw (B) Nut Bolt c (d) Speed lever (e) Actuator shaft 1. Actuator adjustment procedure (1)Position the speed lever (d) in the idle position. (2)Set bolt (c) so that the clearance between the speed lever (d)'s pin and the actuator shaft (e) is approximately L1. (3)Loosen the nut (b) and fully tighten the screw (a). (4)Set the pump speed at N1 and read the rack position when negative pressure P1 is applied to the actuator. (5)Gradually loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1. (6)Apply negative pressure several times and confirm that the lever (d) returns to the idle position at negative pressure '0.' (7)Confirm that rack position is R2 when negative pressure is P2.
----------
L1=2mm N1=500r/min P1=66.7kPa(500mmHg) N2=500r/min R1=9.1mm P2=66.7kPa(500mmHg) R2=9.1mm
----------

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=11deg
----------
a=(130deg)