101606-6560 ZEXEL 9 400 615 522 BOSCH INJECTION-PUMP ASSEMBLY 9400615522 1016066560 me076492

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 522 9400615522

ZEXEL 101606-6560 1016066560

MITSUBISHI ME076492 me076492

Service parts 101606-6560 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9370

3. GOVERNOR 105931-6100

4. SUPPLY PUMP 105210-4700

5. AUTOM. ADVANCE MECHANIS 105643-0490

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7760

11. Nozzle and Holder ME076465

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-4110

14. NOZZLE 105015-6170

15. NOZZLE SET

Include in #1:

101402-4890 as _

101606-6560 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 522 9400615522

ZEXEL 101606-6560 1016066560

MITSUBISHI ME076492 me076492

Zexel num

Bosch num

Firm num

Name

101606-6560
101606-6940

9 400 615 522

ME076492 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 3.8 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 1100

Advance angle deg. 0.5

Load 3/4

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 0.5

Load 4/4

Timer adjustment_03

Pump speed r/min 1250

Advance angle deg. 2.5 2 3

Load 4/4

Timer adjustment_04

Pump speed r/min 1350

Advance angle deg. 5 4.5 5.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

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

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=35mm
----------
a=33deg+-5deg b=(37.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper screw so that speed = bb and the rack position = cc and confirm non-injection. (3)After setting the stopper bolt, confirm non-injection at speed dd. Rack position = ee (non-injection rack position)
----------
aa=50mm bb=1400r/min cc=7.2-0.5mm dd=275r/min ee=(8.5)-0.5mm
----------
a=25deg+-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
----------

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=12deg
----------
a=(1deg)