101603-1830 ZEXEL 9 400 610 040 BOSCH INJECTION-PUMP ASSEMBLY 9400610040 1016031830 me056440

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 040 9400610040

ZEXEL 101603-1830 1016031830

MITSUBISHI ME056440 me056440

Service parts 101603-1830 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4260

3. GOVERNOR 105490-4870

4. SUPPLY PUMP 105210-4151

5. AUTOM. ADVANCE MECHANIS 105614-4100

6. COUPLING PLATE 105662-0590

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6021

11. Nozzle and Holder ME056371

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

13. NOZZLE-HOLDER 105030-5010

14. NOZZLE

105015-5390

15. NOZZLE SET

Include in #1:

101603-1830 as INJECTION-PUMP ASSEMBLY

101603-8090 as _

Cross reference number

BOSCH 9 400 610 040 9400610040

ZEXEL 101603-1830 1016031830

MITSUBISHI ME056440 me056440

Zexel num

Bosch num

Firm num

Name

101603-1830

9 400 610 040

ME056440 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D22 K 14BF INJECTION PUMP ASSY PE6AD 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 131424-5120

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 1-5-3-6- 2-4

Pre-stroke mm 4.5 4.45 4.55

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 9.6

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 112 108.6 115.4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 18.5 15.7 21.3

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 112 111 113

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.6)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 113.5 111 116

Difference in delivery mm3/st. 9 9 9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 120 160

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 850--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 800

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 0.9 0.4 1.4

Timer adjustment_04

Pump speed r/min 1150

Advance angle deg. 3 2.5 3.5

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 4 4 5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target shim dimension: TH (2)Beginning of damper spring operation: DL (3)Excess fuel setting for starting: SXL
----------
TH=2.3mm DL=6.8-0.2mm SXL=R1(9.6)+0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=10deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=21.5deg+-5deg b=29deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Free (at delivery) (2)Rack position = aa (3)Rack position = bb, set the stopper bolt.
----------
aa=13.5mm bb=6-0.5mm
----------
a=(58deg) b=36deg+5deg-7deg c=24deg+-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=325+-5r/min Ra=7.3mm
----------