101603-6600 ZEXEL 9 400 615 135 BOSCH INJECTION-PUMP ASSEMBLY 9400615135 1016036600 me047084

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 135 9400615135

ZEXEL 101603-6600 1016036600

MITSUBISHI ME047084 me047084

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Buy INJECTION-PUMP ASSEMBLY 101603-6600 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-6600 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-8930

3. GOVERNOR 105412-2000

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105643-5160

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6500

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE 105015-6230

15. NOZZLE SET

Include in #1:

101402-0871 as _

101603-6600 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 135 9400615135

ZEXEL 101603-6600 1016036600

MITSUBISHI ME047084 me047084

Zexel num

Bosch num

Firm num

Name

101603-6600

9 400 615 135

ME047084 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D16T * 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 A

Rack position 11.1

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 94.7 93.7 95.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.7+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 10.7 9.2 12.2

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Supplied with torque spring not set. (3)Idle sub spring setting: L1. (4)Setting at shipping
----------
K=7 L1=7.4-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)At shipping (3)Pump speed = aa (4)Pump speed = bb
----------
aa=1400r/min bb=1000r/min
----------
a=30deg+-5deg b=(2deg) c=12deg+-5deg d=11deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=26deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark '2' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=14deg
----------
a=(90deg)

Information:

Table 3
Injector Resistance Measurement
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding.
2 Disconnect the DEF injector from the applicable harness.
3 Inspect the connector for damage or debris (if damaged take photo)
4 Measure the temperature of the injector (aluminum body) C
5 Connect two 398-4987 connectors to the DEF injector. The connectors must be used to prevent damage to the DEF injector connector.
6 Measure the resistance of the DEF injector. Ohms
Table 4
Dosing Accuracy Test
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Follow the Testing and Adjusting, Aftertreatment SCR System Dosing - Test.
2 Remove the injector from the DPF outlet.
3 Take a photograph of the DEF injector mount on the DPF outlet and the tip of the DEF injector.
4 Install the injector on the beaker.
5 Run the DEF System Dosing Accuracy test through Cat ET.
6 Use the breaker to measure the amount of fluid from the dosing test. ml
7 Repeat the test to verify consistency. ml
8 Install the injector back onto the DPF outlet.
Illustration 2 g06068068
DEF Injector Resistance Measurement
Illustration 3 g06067706
Injector Mount on DPF (Outlet Sample Picture)
Illustration 4 g06067753
DEF Injector Tip (Sample Picture)
When troubleshooting requests the DEF quality check, DEF injector resistance measurement or Dosing Accuracy Test, please document results in the Tables shown above.
After completing troubleshooting and performing the Aftertreatment System Functional Test, download a new Product Status Report with all ECM's.
Table 5
Injector Failure Report
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Download "Product Status Report" (PSR) from the engine ECM and send to the email address in the instructions.
2 Download "Warranty Report" (WR) from the engine ECM and send to the email address in the instructions.
3 Take a picture of the injector part number / serial number.
4 Follow the correct TSG based on Table 1 and complete tables 2 through 4 when they apply.
5 Perform an "Aftertreatment System Functional Test".
6 Download "Product Status Report" (PSR) from the engine ECM and send to the email address in the instructions.
7 Submit "TIB Check List", "Product Status Reports", DEF injector deposits photographs, CEM deposit photographs, and DEF injector part number and serial number photograph to the email address in the instructions.
Fill out the Injector Failure Report and send all information including product status reports, warranty reports, DEF injector and mount photos, DEF injector part number and serial number and test results to the email address provided above.