106651-2511 ZEXEL 9 400 616 563 BOSCH INJECTION-PUMP ASSEMBLY 9400616563 1066512511 me151025


106651-2511 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 616 563 9400616563
ZEXEL 106651-2511 1066512511
MITSUBISHI ME151025 me151025

Service parts 106651-2511 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106065-5360
3. GOVERNOR 105487-6680
4. SUPPLY PUMP 105207-1041
5. AUTOM. ADVANCE MECHANIS 105636-1640
6. COUPLING PLATE 105662-0710
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-5721
11. Nozzle and Holder ME056275
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}
13. NOZZLE-HOLDER 105041-4420
14. NOZZLE 105015-5330
15. NOZZLE SET

Include in #1:

106651-2511 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 563 9400616563
ZEXEL 106651-2511 1066512511
MITSUBISHI ME151025 me151025


Zexel num
Bosch num
Firm num
Name
106651-2511 
9 400 616 563 
ME151025  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D22T0 * 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   8-3-600
Overflow valve   131424-4420
Overflow valve opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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)
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   5.1 5.05 5.15
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   700 700 700
Each cylinder's injection qty mm3/st.   137.4 134 140.8
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   6.3+-0.5
Pump speed r/min   225 225 225
Each cylinder's injection qty mm3/st.   18.6 15.9 21.3
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   700 700 700
Average injection quantity mm3/st.   137.4 136.4 138.4
Basic   *
Fixing the lever   *
Boost pressure kPa   52 52
Boost pressure mmHg   390 390
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(12)
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   136.6 132.6 140.6
Difference in delivery mm3/st.   8 8 8
Fixing the lever   *
Boost pressure kPa   52 52
Boost pressure mmHg   390 390
Injection quantity adjustment_05
Adjusting point   D
Rack position   11.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   121 117.4 124.6
Fixing the lever   *
Boost pressure kPa   29.3 28 30.6
Boost pressure mmHg   220 210 230
Injection quantity adjustment_06
Adjusting point   E
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   110 90 130
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   R2(R1-2)
Boost pressure kPa   4 4 4
Boost pressure mmHg   30 30 30
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   11.5
Boost pressure kPa   29.3 28 30.6
Boost pressure mmHg   220 210 230
Boost compensator adjustment_03
Pump speed r/min   600 600 600
Rack position   R1(12)
Boost pressure kPa   38.7 32 45.4
Boost pressure mmHg   290 240 340
Timer adjustment
Pump speed r/min   450--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   400
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   720
Advance angle deg.   2.5 2 3
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106651-2511
N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Lever ratio: RT (3)Target shim dimension: TH (4)Tolerance for racks not indicated: +-0.05mm. (5)Boost compensator cancel stroke: BSL (6)Boost compensator stroke: BCL (7)Damper spring setting (8)Adjust with the load control lever in the full position (variable speed specification). (9)When air cylinder is operating.
----------
RT=1 TH=2mm BSL=2mm BCL=2+-0.1mm
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Speed control lever angle

Test data 106651-2511
F:Full speed I:Idle (1)Pump speed = aa (2)Pump speed = bb (3)Pump speed cc (4)Air cylinder's adjustable range
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aa=1200r/min bb=300r/min cc=815r/min
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a=(10.5deg)+-5deg b=(10deg)+-5deg c=(23deg)+-5deg d=(10.5deg)

0000000901

Test data 106651-2511
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=21deg+-5deg b=37deg+-3deg

Stop lever angle

Test data 106651-2511
N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Rack position bb (4)Free (at delivery)
----------
aa=4.9-0.5mm bb=14mm
----------
a=45deg+7deg-5deg b=25.5deg+-5deg c=(80.5deg)

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=325r/min Ra=6+-0.1mm
----------

0000001601 2-STAGE CHANGEOVER DEVICE

Test data 106651-2511
RFD governor 2 stage changeover mechanism adjustment outline (A) Bolt (B) bolt (c) Nut (D) Return spring (E) Bolt (F) Bolt (G) Screw (H) Bolt (I) Load lever (J) Speed lever (K) Air cylinder (M Air inlet Figure 1 is only for reference. Lever shape, etc, may vary. 1. Minimum-maximum speed specification adjustment (when running) (a) Without applying air to the air cylinder, loosen bolts (A) and (B). (1)High speed return L setting (a) In the speed range Nf~Nf - 300r/min, adjust using the speed adjusting bolt to determine the temporary beginning of high speed control speed. (b) Determine the rack position in the vicinity of Rf using the full load lever. (c) Increase speed and confirm return distance L. (d) Adjust using the tension lever bolt to obtain L. (2)Setting full load rack position Rf (a) Move the load control lever to the full side. (b) Adjust the full load adjusting bolt so that Rf can be obtained, then fix. (3)Setting the beginning of high speed operation Nf (a) Adjust using bolt (E) so that Nf can be obtained, and then fix. (4)Idle control setting (Re, Ni, Rc) (a) Set the speed at Ns + 200r/min and move the load control lever to the idle side. (b) Fix the lever in the position where Re can be obtained. (c) Next, decrease speed to Ni and screw in the idle spring. (d) Adjust to obtain rack position Ri. (e) Increase the speed and after confirming that the rack position is Re at Ns, set the speed at 0. (f) Confirm protrusion position Rc at idle. (5)Damper spring adjustment (a) Increase speed and set the speed at the rack position Rd - 0.1 mm (b) Set using the damper spring so that the rack position Rd can be obtained. (c) When Rd is not specified, Rd = Ri - 0.5 mm. (6)High speed droop confirmation (a) Return the load control lever to the full load lever position. (b) Increase the speed and confirm that Rf can be obtained at Nf r/min. (c) Confirm that speed is Nh at rack position Rh. 2. Variable speed specification adjustment (at operation) (a) Remove return spring (D). (b) Apply air pressure of 245~294 kPa {2.5~3 kg/cm2} to the air cylinder. (c) Perform the following adjustment in this condition. (1)Setting full load rack position Rf' (a) Pull the load lever to the idle side. (b) Obtain rack position Rf' using the nut (C). (Pump speed is Nf'-50 r/min.) (2)Setting full speed Nf' (a) Adjust using bolt (B) so that Nf can be obtained, and then fix. (3)Low speed side setting (a) At 350r/min, set bolt (F) at beginning of governor operation position, then fix. 3. Bolt (A) adjustment (1)Install return spring (D) and perform the adjustments below at air pressure 0. (a) Set at speed Nf using bolt (E). (b) Screw in bolt (A). (c) Screw in 1 more turn from the speed lever contact position (d) Fix bolt (A). (e) At this time confirm that the air cylinder's shaft moves approximately 1 mm towards the governor. 4. Lever operation confirmation using the air cylinder (1)Apply 588 kPa {6 kg/cm2} air pressure to the air cylinder. (2)Confirm that the cylinder piston is moved 50 mm by the spring (D).
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Timing setting

Test data 106651-2511
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(6deg)




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