101606-1903 ZEXEL 9 400 615 475 BOSCH INJECTION-PUMP ASSEMBLY 9400615475 1016061903 me076280


101606-1903 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 475 9400615475
ZEXEL 101606-1903 1016061903
MITSUBISHI ME076280 me076280

Service parts 101606-1903 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-9140
3. GOVERNOR 105931-5272
4. SUPPLY PUMP 105210-4700
5. AUTOM. ADVANCE MECHANIS 105643-0391
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-7550
11. Nozzle and Holder ME076205
12. Open Pre:MPa(Kqf/cm2) 17.7(180)/21.6(220)
13. NOZZLE-HOLDER 105030-4110
14. NOZZLE 105015-7550
15. NOZZLE SET

Include in #1:

101606-1903 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 475 9400615475
ZEXEL 101606-1903 1016061903
MITSUBISHI ME076280 me076280


Zexel num
Bosch num
Firm num
Name
101606-1903 
9 400 615 475 
ME076280  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   3.3 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   12.5
Pump speed r/min   800 800 800
Each cylinder's injection qty mm3/st.   87.3 84.7 89.9
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.   8 6.8 9.2
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.5)
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   87.3 86.3 88.3
Basic   *
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.75
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   85.3 81.3 89.3
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.2
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   86 82 90
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   99 79 119
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   300 300 300
Rack position   R2-0.8
Boost pressure kPa   10 10 10
Boost pressure mmHg   75 75 75
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   R2-0.6
Boost pressure kPa   13.3 12 14.6
Boost pressure mmHg   100 90 110
Boost compensator adjustment_03
Pump speed r/min   300 300 300
Rack position   R2(R1+0. 5)
Boost pressure kPa   23.3 23.3 23.3
Boost pressure mmHg   175 175 175
Timer adjustment
Pump speed r/min   1200
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1300
Advance angle deg.   1.7 1.2 2.2
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   3.5 3 4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101606-1903
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=D11 BCL=0.8+-0.1mm
----------

Speed control lever angle

Test data 101606-1903
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=10deg+-5deg b=(45deg)+-3deg

Stop lever angle

Test data 101606-1903
N:Pump normal 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).
----------
aa=6.5-0.5mm bb=275r/min cc=6.5-0.5mm
----------
a=11.5deg+-5deg b=27deg+-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 101606-1903
(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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