101606-6811 ZEXEL F 01G 09U 04P BOSCH INJECTION-PUMP ASSEMBLY f01g09u04p 1016066811 me076578


 

Information injection-pump assembly

BOSCH F 01G 09U 04P f01g09u04p
ZEXEL 101606-6811 1016066811
MITSUBISHI ME076578 me076578
101606-6811 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH F 01G 09U 04P f01g09u04p
ZEXEL 101606-6811 1016066811
MITSUBISHI ME076578 me076578


Zexel num
Bosch num
Firm num
Name
101606-6811 
101607-1070 
F 01G 09U 04P 
ME076578  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D16 * 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   131424-5520
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   4.2 4.15 4.25
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   11.3
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   74.5 72.3 76.7
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.   8 6.8 9.2
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.3)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   74.5 73.5 75.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   83.5 79.5 87.5
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.4
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   69 65 73
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   146 136 156
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.9 0.4 1.4
Timer adjustment_03
Pump speed r/min   1380
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101606-6811
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=E45
----------

Speed control lever angle

Test data 101606-6811
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101606-6811
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=1400r/min bb=6.5-0.5mm cc=275r/min dd=(8.5)-0.5mm ee=15mm
----------
a=38.5deg+-5deg b=(27deg) c=15.5deg+-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=400r/min Ra=9.2+-0.1mm
----------

Timing setting

Test data 101606-6811
(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=11deg
----------
a=(1deg)




Information:

Start By:a. remove fuel injection linesb. disassemble governor **Only disassemble the governor enough so that tooling (D) of Install Fuel Injection Pump can be installed 1. Remove the plug, and move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to remove the fuel injection pumps.
To prevent possible personal injury carefully follow the steps below.
2. Put tooling (B), except for the 8S4613 Wrench, in position on the fuel pump housing as shown. Lower the handle to center the adjusting screw with the fuel line seat. With the handle down in the locked position, the adjusting screw must just be in contact with fuel line seat (1). If force is needed to lower the handle or there is a gap, remove the tooling, and make an adjustment to the screw.3. Loosen bushing (2) 1/4 of a turn.4. Put tooling (B) in position on the pump housing with the handle down in the locked position as shown.5. Remove bushing (2) from the pump housing.6. Carefully and slowly lift the handle to release the spring force. Remove the tooling. 7. Install tool (C) on fuel pump (4) as shown.8. Remove seal (3) and fuel pump (4) from the fuel pump housing. 9. Remove spacers (5) from the pump housing. There must be a pump installed on either side of the pump to be removed to install tooling (B). If there is no pump, take a pump already removed, and remove the spring so there will be no spring force, and install it in the pump housing. See the topic, Install Fuel Pump. Spacers (5) are the same thickness for each fuel injection pump so they can be mixed. The fuel injection pump plungers and barrels are sets and cannot be mixed.Install Fuel Injection Pumps
1. Install spacers (5) in the fuel pump housing.2. Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.3. Install a fuel pump without its spring so that tool (B) can be installed. See Step 5 for correct fuel pump installation. 4. Install tool (C) on the bonnet of the fuel pump as shown.5. Install the fuel pump in the pump housing with the saw cut (slot) (9) in the gear in alignment with small pin (6) in the lifter assembly and groove (8) in the barrel in alignment with large pin (7) in the pump housing. 6. Install the seal and bushing (2) on the fuel pump.7. Put tooling (B) in position on the fuel pump housing as shown.8. Lower the handle slowly and carefully. If the fuel pump is not installed correctly, the handle will not go all the way down. Do not try to use force on it. Remove and install the tooling and the fuel pump again.9. Make sure the seal is in its correct position, and start

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