Information injection-pump assembly
BOSCH
9 400 615 501
9400615501
ZEXEL
101606-6260
1016066260
MITSUBISHI
ME076346
me076346

Rating:
Service parts 101606-6260 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME035655
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
101606-6260
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-5328
as _
Cross reference number
BOSCH
9 400 615 501
9400615501
ZEXEL
101606-6260
1016066260
MITSUBISHI
ME076346
me076346
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.8
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
65
63
67
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
Each cylinder's injection qty
mm3/st.
10.5
9
12
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.8)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
65
64
66
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(10.8)
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
77.5
75.5
79.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.4
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
59.7
55.7
63.7
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
14.1+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
90
70
110
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
0.8
Timer adjustment_04
Pump speed
r/min
1200
Advance angle
deg.
2.6
2.1
3.1
Timer adjustment_05
Pump speed
r/min
1500
Advance angle
deg.
5.5
5
6
Remarks
Finish
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=D39
----------
----------
T1=D39
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=10deg+-5deg b=42deg+-3deg
----------
----------
a=10deg+-5deg b=42deg+-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.
(4)Free (at shipping)
----------
aa=1550r/min bb=7.2-0.5mm cc=275r/min dd=8.2mm ee=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-5deg
----------
aa=1550r/min bb=7.2-0.5mm cc=275r/min dd=8.2mm ee=17.4mm
----------
a=38.5deg+-5deg b=(27deg) c=17deg+-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=16deg
----------
a=(1deg)
----------
aa=16deg
----------
a=(1deg)
Information:
6V7070 Heavy-Duty Digital MultimeterThe 6V7070 Heavy-Duty Digital Multimeter is a completely portable, hand held instrument with a digital display. This multimeter is built with extra protection against damage in field applications, and is equipped with seven functions and 29 ranges. The 6V7070 Multimeter has an instant ohms indicator that permits continuity checks for fast circuit inspection. It also can be used for troubleshooting small value capacitors.The 6V7800 Regular-Duty Digital Multimeter (a low cost option to the Heavy-Duty Multimeter) is also available; however, the 6V7800 Multimeter does not have the 10A range or the instant ohms feature of the 6V7070 Multimeter. Make reference to Special Instruction, Form No. SEHS7734 for more complete information for use of the 6V7070 and 6V7800 MultimetersBattery
Never disconnect any charging unit circuit or battery circuit cable from battery when the charging unit is operated. A spark can cause an explosion from the flammable vapor mixture of hydrogen and oxygen that is released from the electrolyte through the battery outlets. Injury to personnel can be the result.
The battery circuit is an electrical load on the charging unit. The load is variable because of the condition of the charge in the battery. Damage to the charging unit can result if the connections (either positive or negative) between the battery and charging unit are broken while the charging unit is in operation. This is because the battery load is lost and there is an increase in charging voltage. High voltage can damage, not only the charging unit, but also the regulator and other electrical components.Use the 6V4930 Battery Load Tester, the 8T0900 Clamp-On Ammeter and the 6V7070 Multimeter to load test a battery that does not hold a charge when in use. See Special Instruction, Form No. SEHS8268 for the correct procedure and specifications to use.Charging System
The condition of charge in the battery at each regular inspection will show if the charging system operates correctly. An adjustment is necessary when the battery is constantly in a low condition of charge or a large amount of water is needed (more than one ounce of water per cell per week or per every 100 service hours).When it is possible, make a test of the charging unit and voltage regulator on the engine, and use wiring and components that are a permanent part of the system. Off-engine (bench) testing will give a test of the charging unit and voltage regulator operation. This testing will give an indication of needed repair. After repairs are made, again make a test to give proof that the units are repaired to their original condition of operation.Before the start of on-engine testing, the charging system and battery must be checked as shown in the Steps that follow:1. Battery must be at least 75% (1.225 Sp.Gr.) fully charged and held tightly in place. The Battery holder must not put too much stress on the battery.2. Cables between the battery, starter and engine ground must be the correct size. Wires and cables must be free of corrosion and