101603-6311 ZEXEL 9 400 615 120 BOSCH INJECTION-PUMP ASSEMBLY 9400615120 1016036311 me035599

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 120 9400615120

ZEXEL 101603-6311 1016036311

MITSUBISHI ME035599 me035599

Service parts 101603-6311 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9730

3. GOVERNOR 105931-2670

4. SUPPLY PUMP 105210-4641

5. AUTOM. ADVANCE MECHANIS 105692-0010

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5980

11. Nozzle and Holder ME035749

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

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE 105015-5660

15. NOZZLE SET

Include in #1:

101431-4070 as _

101603-6311 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 120 9400615120

ZEXEL 101603-6311 1016036311

MITSUBISHI ME035599 me035599

Zexel num

Bosch num

Firm num

Name

101603-6311
101606-1590

9 400 615 120

ME035599 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D14T 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 2.95 3.05

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 12.1

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 88 85.4 90.6

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 10.5 9 12

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.1)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 88 87 89

Basic *

Fixing the lever *

Boost pressure kPa 49.3 49.3

Boost pressure mmHg 370 370

Injection quantity adjustment_04

Adjusting point C

Rack position (R1-0.8)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 67 65 69

Fixing the lever *

Boost pressure kPa 18.7 18.7 18.7

Boost pressure mmHg 140 140 140

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 90 130

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-1.1

Boost pressure kPa 13.3 13.3 13.3

Boost pressure mmHg 100 100 100

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position (R1-0.8)

Boost pressure kPa 18.7 17.4 20

Boost pressure mmHg 140 130 150

Boost compensator adjustment_03

Pump speed r/min 700 700 700

Rack position R1(12.1)

Boost pressure kPa 36 29.3 42.7

Boost pressure mmHg 270 220 320

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=B44 BCL=1.1+-0.1mm
----------

Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C3=(8deg) t1=2--sec. t2=2--sec.
----------
N1=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=0.5--deg C2=8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=(41deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at speed = rated point and rack position = aa (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt , confirm non-injection at pump speed bb. Rack position = cc (non-injection rack position). (3)Rack position = approximately dd (4)Free (at shipping)
----------
aa=(7.5)mm bb=275r/min cc=(9)mm dd=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-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
----------

0000001601 RACK SENSOR

R:Rack position (mm) V:Voltage (V) After installing the rack sensor, confirm the output value (VR).
----------
N1=- Ra=R1(12.1)mm VR=1.99+-0.01V
----------

Timing setting

(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=14deg
----------
a=(0deg)