101603-6810 ZEXEL 9 400 615 145 BOSCH INJECTION-PUMP ASSEMBLY 9400615145 1016036810 me076006

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 145 9400615145

ZEXEL 101603-6810 1016036810

MITSUBISHI ME076006 me076006

Service parts 101603-6810 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9690

3. GOVERNOR 105931-3800

4. SUPPLY PUMP 105210-4700

5. AUTOM. ADVANCE MECHANIS 105643-0180

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6780

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE

105015-6440

15. NOZZLE SET

Include in #1:

101603-6810 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-1630 as _

Cross reference number

BOSCH 9 400 615 145 9400615145

ZEXEL 101603-6810 1016036810

MITSUBISHI ME076006 me076006

Zexel num

Bosch num

Firm num

Name

101603-6810
101606-6330

9 400 615 145

ME076006 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D16 * K 14BE INJECTION PUMP ASSY PE6A 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 131424-5520

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 3.3 3.25 3.35

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 11.4

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 54.5 52 57

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point D

Rack position 8.7+-0.5

Pump speed r/min 500 500 500

Each cylinder's injection qty mm3/st. 7.6 5.9 9.3

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 54.5 53.5 55.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.4

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 79.8 75.8 83.8

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.4)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 48.5 44.5 52.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position 14.3+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 73 63 83

Fixing the lever *

Rack limit *

Injection quantity adjustment_07

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 8.7 7 10.4

Fixing the rack *

Remarks
(check)

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1200

Advance angle deg. 2.7 2.2 3.2

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=B07
----------

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:Pump normal S:Stop the pump. (1)At the rated pump speed and rack position aa, set the stopper bolt. (Confirm that there is no 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=6.7mm bb=275r/min cc=(8.3)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 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)Turn adjusting screw (C) to adjust the start of aneroid compensator operation. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Turn adjusting screw (C) to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=1450r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=(0.1~0.5)mm
----------
Ra=R1+0.4mm Rb=R1-0.2+-0.2mm Rc=R1-0.8+-0.1mm Pa=94.6+4kPa(710+30mmHg) Pb=79.4kPa(596mmHg) Pc=61.6kPa(462mmHg) Q1=(79.8)+-2cm3/1000st Q2=- Q3=(52)+-2cm3/1000st

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=16deg
----------
a=(1deg)