101606-6960 ZEXEL 9 400 615 545 BOSCH INJECTION-PUMP ASSEMBLY 9400615545 1016066960 me086602

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 615 545 9400615545

ZEXEL 101606-6960 1016066960

MITSUBISHI ME086602 me086602

Service parts 101606-6960 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9460

3. GOVERNOR 105921-4220

4. SUPPLY PUMP 105220-5150

5. AUTOM. ADVANCE MECHANIS 105672-0130

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-4310

11. Nozzle and Holder ME086575

12. Open Pre:MPa(Kqf/cm2) 17.7(180)

13. NOZZLE-HOLDER 105048-3000

14. NOZZLE 105017-0240

15. NOZZLE SET

Include in #1:

101401-7213 as _

101401-7214

101606-6960 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 545 9400615545

ZEXEL 101606-6960 1016066960

MITSUBISHI ME086602 me086602

Zexel num

Bosch num

Firm num

Name

101606-6960
101607-1230

9 400 615 545

ME086602 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D31 * 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 131424-6720

Overflow valve opening pressure kPa 191 157 225

Overflow valve opening pressure kgf/cm2 1.95 1.6 2.3

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive 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 10.3

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 41.1 39.5 42.7

Max. variation between cylinders % 0 -2.5 2.5

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

Average injection quantity mm3/st. 8.3 7 9.6

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.3)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 41.1 40.1 42.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 46.6 42.6 50.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.45

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 41 37 45

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position (R1+0.85 )

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 36.1 32.1 40.1

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 63 63 68

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

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=E52
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=37deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop (1)Free (at shipping) (2)Use the hole at R = aa (3)Rack position corresponding to bb (4)Set the stopper bolt at speed = cc and rack position = dd. (5)After setting the stopper bolt, confirm non-injection at speed ee. (Rack position = ff or less)
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=275r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg

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=(2deg)