101603-6062 ZEXEL 9 400 615 107 BOSCH INJECTION-PUMP ASSEMBLY 9400615107 1016036062 me035626


101603-6062 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 107 9400615107
ZEXEL 101603-6062 1016036062
MITSUBISHI ME035626 me035626

Service parts 101603-6062 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-9690
3. GOVERNOR 105931-2431
4. SUPPLY PUMP 105210-4700
5. AUTOM. ADVANCE MECHANIS 105643-0070
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-5990
11. Nozzle and Holder ME035748
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105031-3900
14. NOZZLE 105015-5670
15. NOZZLE SET

Include in #1:

101603-6062 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 107 9400615107
ZEXEL 101603-6062 1016036062
MITSUBISHI ME035626 me035626


Zexel num
Bosch num
Firm num
Name
101603-6062 
101606-1060 
9 400 615 107 
ME035626  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D15 * 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   131424-5520
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)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   3.6 3.55 3.65
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   11
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   60 58.1 61.9
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   10+-0.5
Pump speed r/min   275 275 275
Each cylinder's injection qty mm3/st.   10 8.9 11.1
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(11)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   60 59 61
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.5
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   80 76 84
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.25
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   43.7 39.7 47.7
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   80 75 85
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1250--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1350
Advance angle deg.   2.4 1.9 2.9
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-6062
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C16
----------

Speed control lever angle

Test data 101603-6062
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=42deg+-3deg

Stop lever angle

Test data 101603-6062
N:Engine manufacturer's normal use S:Stop the pump. (1)Free (at shipping) (2)Rack position = approximately aa. (3)Set the stopper bolt at speed = rated point and rack position = bb (non-injection rack position). Confirm non-injection. (4)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=17.4mm bb=(7)mm cc=275r/min dd=(8)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-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=400+-5r/min Ra=9.2mm
----------

Timing setting

Test data 101603-6062
(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(1deg)




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