101608-6060 ZEXEL 9 400 611 605 BOSCH INJECTION-PUMP ASSEMBLY 9400611605 1016086060 me170458

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 611 605 9400611605

ZEXEL 101608-6060 1016086060

MITSUBISHI ME170458 me170458

Service parts 101608-6060 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9690

3. GOVERNOR 105932-3040

4. SUPPLY PUMP 105210-4700

5. AUTOM. ADVANCE MECHANIS 105643-0180

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6780

11. Nozzle and Holder ME076000

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

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE

105015-6440

15. NOZZLE SET

Include in #1:

101608-6060 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-0544 as _

Cross reference number

BOSCH 9 400 611 605 9400611605

ZEXEL 101608-6060 1016086060

MITSUBISHI ME170458 me170458

Zexel num

Bosch num

Firm num

Name

101608-6060
101608-6061

9 400 611 605

ME170458 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D16 * K 14BE 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 3.3 3.25 3.35

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 11.4

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 54.5 52.9 56.1

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point D

Rack position 8.7+-0.5

Pump speed r/min 500 500 500

Each cylinder's injection qty mm3/st. 7.6 6.5 8.7

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 54.5 53.5 55.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.4

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 79.8 75.8 83.8

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1(11.4)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 48.5 44.5 52.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 73 63 83

Fixing the lever *

Rack limit *

Injection quantity adjustment_07

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 8.7 7.4 10

Fixing the rack *

Remarks
(check)

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1200

Advance angle deg. 2.7 2.2 3.2

Timer adjustment_04

Pump speed r/min 1500

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=D53
----------

Speed control lever angle

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

----------
a=18.5deg+-5deg b=41deg+-3deg

Stop lever angle

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 (speed lever full, speed = ff). (4)Free (at delivery)
----------
aa=1450r/min bb=4.7-0.5mm cc=275r/min dd=(6.3)mm ee=15mm ff=0r/min
----------
a=38.5deg+-5deg b=(29deg) c=17deg+-5deg

0000001501 LEVER

(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=41deg+-3deg c=18.5deg+-5deg

0000001601 ACS

(A) Housing (B) Snap ring (C) adjusting screw (D) Set screw (E): Push rod (F) Spacer 1. Adjustment of the aneroid compensator (1)Adjust with the (D) set screw so that the clearance between the (A) housing and (B) snap ring is L1. (2)Select the push rod (E) so that the distance from the end surface of the (F) spacer becomes L2. (3)(C) Turn the screw to adjust the beginning of aneroid compensator operation. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Adjust using screw C to obtain the performance shown in the graph above. (3)After final adjustment, confirm that the gap between housing (A) and snapring (B) is L3.
----------
N1=1450r/min L1=1.4~1.7mm L2=0.5+-0.5mm L3=0.1~0.5mm
----------
Ra=R1+0.4mm Rb=R1-0.8+-0.1mm Pa=94.6+-4kPa(710+-30mmHg) Pb=61.6kPa(462mmHg) Q1=(79.8)+-2cm3/1000st Q2=(52)+-2cm3/1000st

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=16deg
----------
a=(1deg)