101607-6200 ZEXEL 9 400 615 681 BOSCH INJECTION-PUMP ASSEMBLY 9400615681 1016076200 me076999


101607-6200 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 615 681 9400615681
ZEXEL 101607-6200 1016076200
MITSUBISHI ME076999 me076999

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Cross reference number

BOSCH 9 400 615 681 9400615681
ZEXEL 101607-6200 1016076200
MITSUBISHI ME076999 me076999


Zexel num
Bosch num
Firm num
Name
101607-6200 
101608-1120 
9 400 615 681 
ME076999  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D17 * 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   131424-8420
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   3.2 3.15 3.25
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   12
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   85.1 82.5 87.7
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   9.5+-0.5
Pump speed r/min   800 800 800
Each cylinder's injection qty mm3/st.   10.8 9.2 12.4
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   85.1 84.1 86.1
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.85
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   99.9 95.9 103.9
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   91 81 101
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1100
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1300
Advance angle deg.   2.5 2.5 3.5
Timer adjustment_03
Pump speed r/min   1450
Advance angle deg.   6 5.5 6.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101607-6200
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=G43
----------

Speed control lever angle

Test data 101607-6200
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=(42deg)+-3deg

Stop lever angle

Test data 101607-6200
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 delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg

0000001501 LEVER

Test data 101607-6200
(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=(42deg)+-3deg c=18.5deg+-5deg

0000001601 LEVER

Test data 101607-6200
(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.
----------

----------

Timing setting

Test data 101607-6200
(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=10deg
----------
a=(3deg)




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