101603-6490 ZEXEL 9 400 615 129 BOSCH INJECTION-PUMP ASSEMBLY 9400615129 1016036490 me056527

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 129 9400615129

ZEXEL 101603-6490 1016036490

MITSUBISHI ME056527 me056527

Service parts 101603-6490 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-4260

3. GOVERNOR 105490-5100

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:

101603-6490 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-1512 as _

Cross reference number

BOSCH 9 400 615 129 9400615129

ZEXEL 101603-6490 1016036490

MITSUBISHI ME056527 me056527

Zexel num

Bosch num

Firm num

Name

101603-6490
101606-1390

9 400 615 129

ME056527 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D22 * 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 131424-5120

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 9.9

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 120 116.6 123.4

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(9.9)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 120 119 121

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.9)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 123.7 121.2 126.2

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. 140 100 180

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 900

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)Damper spring setting: DL (2)Excess fuel setting for starting: SXL
----------
DL=6-0.2mm SXL=R1+0.2mm
----------

Speed control lever angle

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

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

0000000901

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

----------
a=25deg+-5deg b=30deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=2.5mm bb=21mm
----------
a=71deg+-5deg b=54deg+-5deg c=(9.5deg)

0000001501 ACS

Aneroid compensator adjustment (1)Adjust the clearance between the aneroid compensator's main body and the push rod to L1. (2)Pump speed N1 at load lever's full position. (3)Screw in the aneroid compensator body to obtain the performance shown in the graph above.
----------
L1=0.1~0.5mm N1=700r/min
----------
Ra=9.9mm Rb=(9.2)mm P1=(88.6)kPa((665)mmHg) P2=69+-0.7kPa(518+-5mmHg) Q1=120+-1cm3/1000st Q2=100.5+-1cm3/1000st

0000001601 MICRO SWITCH

Microswitch adjustment (CLOSED type) 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
----------