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


101606-6960 INJECTION-PUMP ASSEMBLY
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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:

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

Test data 101606-6960
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

Test data 101606-6960
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

Test data 101606-6960
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

Test data 101606-6960
(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)




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