101602-1551 ZEXEL 9 400 614 745 BOSCH INJECTION-PUMP ASSEMBLY 9400614745 1016021551 me088986

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 745 9400614745

ZEXEL 101602-1551 1016021551

MITSUBISHI ME088986 me088986

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Service parts 101602-1551 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9900

3. GOVERNOR 105400-9080

4. SUPPLY PUMP

105210-5250

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156639-1020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5031

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105048-3590

14. NOZZLE

105017-1040

15. NOZZLE SET

Include in #1:

101602-1551 as INJECTION-PUMP ASSEMBLY

103672-0400 as _

Cross reference number

BOSCH 9 400 614 745 9400614745

ZEXEL 101602-1551 1016021551

MITSUBISHI ME088986 me088986

Zexel num

Bosch num

Firm num

Name

101602-1551

9 400 614 745

ME088986 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D34T 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)
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 3.5 3.45 3.55

Beginning of injection position
Drive 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 A

Rack position 9.8

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 71.5 70.5 72.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.4+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 8 6.7 9.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 65 65 70

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=9
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=5deg+-5deg b=24deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12.5deg
----------
a=(130deg)

Information:

Introduction
The problem identified below does not have a permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
There have been some instances of faults with the 459-7216 DEF Injector & Mounting Gp. The faults can lead to the Diesel Exhaust Fluid (DEF) injector not dosing correctly. Diagnostic trouble codes and operator inducements may become active due to these faults.Solution
Follow the correct troubleshooting procedure for any diagnostic codes related to the DEF system. Refer to Troubleshooting for the correct procedure. Diagnostic code 3361–5 Aftertreatment #1 DEF Dosing Unit : Current Below Normal has been reported, which may lead to operator inducement diagnostic codes 5246-15 Aftertreatment SCR Operator Inducement : Severity : High - least severe (1) and 5246-16 Aftertreatment SCR Operator Inducement : Severity : High - moderate severity.If the troubleshooting procedure indicates a DEF injector fault, perform the following procedure:
Ensure that the latest engine software is installed on the engine ECM. Refer to Troubleshooting, ECM Software - Install for the correct procedure.
Illustration 1 g06123677
View of the 459-7216 DEF Injector & Mounting Gp
(1) DEF injector part number
(2) Cavity number
Record the DEF injector part number (1), serial number, and cavity number (2).Note: The cavity number will be either a "1", a "2", or a "3".
If the DEF injector serial number is between "SN150702094314" and "SN160722000000" and the cavity number is "1", continue with this procedure.If the DEF injector serial number is outside of the range specified above, proceed to Test Step 4.If the cavity number is "2" or a "3", proceed to Test Step 4.
Install a replacement DEF injector. Refer to