Information injection-pump assembly
BOSCH
9 400 615 545
9400615545
ZEXEL
101606-6960
1016066960
MITSUBISHI
ME086602
me086602
Rating:
Service parts 101606-6960 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME086575
12.
Open Pre:MPa(Kqf/cm2)
17.7(180)
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 615 545
9400615545
ZEXEL
101606-6960
1016066960
MITSUBISHI
ME086602
me086602
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
131424-6720
Overflow valve opening pressure
kPa
191
157
225
Overflow valve opening pressure
kgf/cm2
1.95
1.6
2.3
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Drive side NO.1
Drive 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
10.3
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
41.1
39.5
42.7
Max. variation between cylinders
%
0
-2.5
2.5
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
Average injection quantity
mm3/st.
8.3
7
9.6
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.3)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
41.1
40.1
42.1
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.1
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
46.6
42.6
50.6
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.45
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
41
37
45
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
(R1+0.85
)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
36.1
32.1
40.1
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
63
63
68
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1150--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1600
Advance angle
deg.
5
4.5
5.5
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=E52
----------
----------
T1=E52
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=26deg+-5deg b=37deg+-3deg
----------
aa=40mm
----------
a=26deg+-5deg b=37deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop
(1)Free (at shipping)
(2)Use the hole at R = aa
(3)Rack position corresponding to bb
(4)Set the stopper bolt at speed = cc and rack position = dd.
(5)After setting the stopper bolt, confirm non-injection at speed ee. (Rack position = ff or less)
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=275r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-5deg
----------
aa=40mm bb=16mm cc=1700r/min dd=6.5-0.5mm ee=275r/min ff=8mm
----------
a=8deg+-5deg b=15deg+-5deg c=25deg+-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=12deg
----------
a=(2deg)
----------
aa=12deg
----------
a=(2deg)
Information:
Start By:a. remove flywheel The crankshaft rear seal and wear sleeve come as a set and must be installed as a set. If a replacement of the seal is to be made, a replacement of the wear sleeve must also be made. 1. Make at least three holes in seal (1) with a hammer and a sharp punch.2. Use tool (A) to remove seal (1). 3. Install tool (C) in the seal bore.4. Install tool (B) between tool (C) and wear sleeve (2). Turn tool (B) until the tool makes a dent (crease) in wear sleeve (2). Do this in three or more places until the wear sleeve is loose.5. Remove tools (B) and (C), and remove wear sleeve (2) from the crankshaft.Install Crankshaft Rear Seal And Wear Sleeve
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instructions, Form No. SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
1. Install the rear crankshaft seal and wear sleeve with tooling (D). Use the procedures which follow: a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the crankshaft outside diameter before the wear sleeve is installed on the crankshaft. Do not let any Quick Cure Primer or Retaining Compound get on the lip of the seal.b. Install locator (3) and the bolts on crankshaft (4).c. The seal and wear sleeve must be installed dry. Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the rear seal group for an engine is different from the front seal group. If a seal group is installed on the wrong side of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
d. Put wear sleeve (2) and seal (7) as a unit in position on locator (3).e. Put installer (5) in position on locator (3).f. Put clean engine oil on the face of nut (6) and its contact area on installer (5). Install nut (6) on locator (3).g. Tighten nut (6) until installer (5) makes contact with locator (3).h. Remove tooling (D) from the crankshaft seal and wear sleeve. Tooling (D) will install the seal and wear sleeve to the correct depth on the crankshaft.End By:a. install flywheel
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instructions, Form No. SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
1. Install the rear crankshaft seal and wear sleeve with tooling (D). Use the procedures which follow: a. Clean and make a preparation of the wear sleeve inside diameter and crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to the crankshaft outside diameter before the wear sleeve is installed on the crankshaft. Do not let any Quick Cure Primer or Retaining Compound get on the lip of the seal.b. Install locator (3) and the bolts on crankshaft (4).c. The seal and wear sleeve must be installed dry. Make sure the seal is installed with the part number and the arrows showing crankshaft rotation toward the outside.
The front and rear seals and wear sleeves have different spiral grooves in the seal. Because of this type of design, the rear seal group for an engine is different from the front seal group. If a seal group is installed on the wrong side of the engine, oil can actually be taken out of the engine instead of moving the oil back into the engine.
d. Put wear sleeve (2) and seal (7) as a unit in position on locator (3).e. Put installer (5) in position on locator (3).f. Put clean engine oil on the face of nut (6) and its contact area on installer (5). Install nut (6) on locator (3).g. Tighten nut (6) until installer (5) makes contact with locator (3).h. Remove tooling (D) from the crankshaft seal and wear sleeve. Tooling (D) will install the seal and wear sleeve to the correct depth on the crankshaft.End By:a. install flywheel