101606-6791 ZEXEL F 01G 09U 04N BOSCH INJECTION-PUMP ASSEMBLY f01g09u04n 1016066791 me076551


101606-6791 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH F 01G 09U 04N f01g09u04n
ZEXEL 101606-6791 1016066791
MITSUBISHI ME076551 me076551

Include in #1:

Cross reference number

BOSCH F 01G 09U 04N f01g09u04n
ZEXEL 101606-6791 1016066791
MITSUBISHI ME076551 me076551


Zexel num
Bosch num
Firm num
Name
101606-6791 
101607-1080 
F 01G 09U 04N 
ME076551  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   4.2 4.15 4.25
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   11.3
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   74.5 72.3 76.7
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(11.3)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   74.5 73.5 75.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   83.5 79.5 87.5
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.4
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   69 65 73
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   146 136 156
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.9 0.4 1.4
Timer adjustment_03
Pump speed r/min   1380
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101606-6791
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=E45
----------

Speed control lever angle

Test data 101606-6791
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101606-6791
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=6.5-0.5mm 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=9.2+-0.1mm
----------

0000001601 LEVER

Test data 101606-6791
(A) Accelerator lever stopper bolt (B) Link (c) Nut (D) Lever (E) Pin (f) lever (G) Stopper bolt (H) Return spring (J) Pin (E) contacts lever. (K) Load sensor terminal (1)Black (2)Blue-yellow (3)Blue-red Setting the accelerator lever angle, load sensor adjustment 1. Accelerator lever setting method (1)Position the speed lever against the idle stopper bolt and fix. (2)Screw in the accelerator lever stopper bolt (A) and back off the stopper bolt (A) from the position where the accelerator lever pin contacts the speed lever and set. (Gap: approx. 1 mm) Tightening torque: 4.9~7 N.m {0.5~0.7 kgf.m} 2. Load sensor adjustment (See fig 1) (1)Load sensor output measuring circuit Apply DC5+-0.01V to the load sensor terminals and measure the output voltage. (2)Load sensor output adjustment procedure Hold the speed lever against the full side stopper bolt and fix. Adjust the load sensor output voltage to VF = 0.417+-0.1 V using the link (B) and then fix temporarily using nut (C). Turn the speed lever from the idle side to the full side and confirm that output voltage VF = 0.417+-0.1 V is obtained. Confirm several times and then fix using nut (C). Tightening torque: 3.4~4.9 N.m {0.35~0.5 kgf.m} 3. Setting the step motor's idle side stopper bolt After adjustment in previous 1 and 2, position speed lever against idle stopper bolt and fix. Then, screw in stopper bolt G until step motor lever D's pin E contacts lever F. Back off 10+2 deg (approx. 3.5 mm) from this position and fix G. (See fig. 3) 4. Speed lever return confirmation (1)Remove return spring (H) and confirm that the speed lever is returned to the idle position by the torsion spring. (2)Reinstall the return spring (H) in its original position.
----------

----------

0000001701 TAMPER PROOF

Test data 101606-6791
1. Method for setting tamperproof proofing (1)Perform after governor adjustment (torque cam phase adjustment). (2)Increase the full rack position to aa using the load lever. (3)At N = N1, push in screw (A) until Ra. (4)Temporarily caulk using the tip of a screwdriver (5)Confirm that the rack at that time is Rb. (6)Lock using setscrew (B). (Tightening torque = T) (7)Pressfit (C) after applying adhesive. (8)Readjust the full rack using the load lever.
----------
aa=(0.4)mm N1=850r/min Ra=(R1+0.3)mm Rb=(R1+0.3)mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)

Timing setting

Test data 101606-6791
(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)-
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aa=11deg
----------
a=(1deg)




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