101606-6510 ZEXEL 9 400 615 518 BOSCH INJECTION-PUMP ASSEMBLY 9400615518 1016066510 me076487


101606-6510 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 518 9400615518
ZEXEL 101606-6510 1016066510
MITSUBISHI ME076487 me076487

Include in #1:

Cross reference number

BOSCH 9 400 615 518 9400615518
ZEXEL 101606-6510 1016066510
MITSUBISHI ME076487 me076487


Zexel num
Bosch num
Firm num
Name
101606-6510 
101606-6800 
9 400 615 518 
ME076487  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D16 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   3.8 3.75 3.85
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   11.8
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   71.3 69.2 73.4
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   285 285 285
Each cylinder's injection qty mm3/st.   11.9 10.1 13.7
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.8)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   71.3 70.3 72.3
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(11.8)
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   80.9 76.9 84.9
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   D
Rack position   R1+0.65
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   70.4 66.4 74.4
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   F
Rack position   R1+1.25
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   69.5 65.5 73.5
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   I
Rack position   14.3+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   108 88 128
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1250
Advance angle deg.   2.5 2 3
Timer adjustment_03
Pump speed r/min   1350
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101606-6510
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=D91
----------

Speed control lever angle

Test data 101606-6510
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=(37.5deg)+-3deg

Stop lever angle

Test data 101606-6510
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=1400r/min bb=7.2-0.5mm cc=275r/min dd=(8.5)-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=400r/min Ra=9.6+-0.1mm
----------

0000001601 RACK SENSOR

Test data 101606-6510
V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------

Timing setting

Test data 101606-6510
(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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