101606-6540 ZEXEL 9 400 615 520 BOSCH INJECTION-PUMP ASSEMBLY 9400615520 1016066540 me076490


101606-6540 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 520 9400615520
ZEXEL 101606-6540 1016066540
MITSUBISHI ME076490 me076490

Include in #1:

Cross reference number

BOSCH 9 400 615 520 9400615520
ZEXEL 101606-6540 1016066540
MITSUBISHI ME076490 me076490


Zexel num
Bosch num
Firm num
Name
101606-6540 
101606-6820 
9 400 615 520 
ME076490  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 101606-6540
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 101606-6540
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

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

Stop lever angle

Test data 101606-6540
N:Engine manufacturer's normal use 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). (3)Rack position = approximately ee. (4)Free (at shipping)
----------
aa=1400r/min bb=7.2-0.5mm cc=275r/min dd=(8.5)-0.5mm ee=15mm
----------
a=38.5deg+-5deg b=(27deg) c=15.5deg+-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
----------

Timing setting

Test data 101606-6540
(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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