101606-1021 ZEXEL 9 400 615 422 BOSCH INJECTION-PUMP ASSEMBLY 9400615422 1016061021 me047436

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 422 9400615422

ZEXEL 101606-1021 1016061021

MITSUBISHI ME047436 me047436

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Service parts 101606-1021 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-8960

3. GOVERNOR 105490-5290

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105643-0120

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7420

11. Nozzle and Holder ME047446

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-4110

14. NOZZLE 105015-7230

15. NOZZLE SET

Include in #1:

101606-1021 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-6110 as _

Cross reference number

BOSCH 9 400 615 422 9400615422

ZEXEL 101606-1021 1016061021

MITSUBISHI ME047436 me047436

Zexel num

Bosch num

Firm num

Name

101606-1021

9 400 615 422

ME047436 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D16T * K 14BF INJECTION PUMP ASSY PE6AD PE

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 9.8

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 94.8 93.8 95.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point G

Rack position 8.1+-0.5

Pump speed r/min 340 340 340

Average injection quantity mm3/st. 13.8 12.3 15.3

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)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)RACK LIMIT: RAL (5)Main spring setting (6)Damper spring setting (7)Set idle sub-spring
----------
RT=1 TH=2.5mm RAL=13.2+-0.1mm
----------

Speed control lever angle

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

----------
a=(20deg)+-5deg b=(3deg)+-5deg

0000000901

F:Full load (1)Fix the lever at the full load position
----------

----------
a=81.5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=2.5mm bb=21mm
----------
a=71deg+-5deg b=20deg+-5deg c=(9.5deg)

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=14deg
----------
a=(1deg)

Information:

Illustration 6 g06613192
Gray locking wedge removed from ECM connector
Remove gray locking wedge from 86-pin connector to provide access to release the DT Pins.Note: Circuit U937 to be removed from pin location number 24 and transferred to pin location 73.Note: Cloth tape will need to be removed to the split in the harness main bundle.Note: The U937 wire can then be routed into the opposite branch to gain enough free length to make the connection.Note: The U939 wire removed from pin location 73 has adequate length to be loaded into location 16.
Transfer and relocate the wires as detailed in Table 2.
Reinstall the locking wedge (B) when all wires have been transferred and relocated.
Illustration 7 g06613197
View of back of ECM connector with connector cover (D) removed
Apply cloth tape to both wire branches from the main bundle of wires up the branches to the harness strain relief strap location.
Illustration 8 g06613199
Connector cover (D) reinstalled with harness secured
(1) 3S-2093 Cable Strap
(D) Connector cover
Reinstall connector cover (D) and secure the harness branches using two cable straps (1).
Use caution when re-engaging the connector with the ECM.
Tighten allen head screw (A).Note: In certain cases, U937 may require lengthening to provide adequate strain relief when relocated in pin 73.Note: Refer to "Soldered Splice","Deutsch connector", or "Sealed Mechanical Splice" for the proper way to extend circuit U937.Soldered Splice
A soldered spliced can be made to extend the wire. Soldered connection will need to be insulated using an appropriately sized adhesive head shrink sleeve.
Illustration 9 g06613210
U937 removed
Remove U937 from ECM connector.
Cut pin off end of wire.
Strip wire 7.5 mm (0.30 inch).
Illustration 10 g06613213
Additional wire soldered to circuit U937
Solder to additional wire to extend U937 and install appropriate sized adhesive head shrink sleeve.
Install pin on end of U937.
Insert U937 into pin 73.
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connector.Deutsch connector
Table 3
Required Parts
Qty Part Number Part Name
1 115-8109 Wire Splice Note: The deutsch connector is a field serviceable alternative to permanent splices. It is made from the same high-quality silicone elastomer as used for the Deutsch connector seals and grommets. The splice body houses a contact retention system that secures a mated pair of contacts in a compact environmentally sealed unit. This splice can also be serviced with standard deutsch connector tools.
Illustration 11 g06613218
Deutsch connector section view
Illustration 12 g06613221
Deutsch connector splice installed
Illustration 13 g06613224
Sufficient strain relief for deutsch connector
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connectorSealed Mechanical Splice
Table 4
Required Parts
Qty Part Number Part Name
1 136-4877 Wire Splice Note: Sealed mechanical splices have head-shrinkable, environmentally sealed sleeves.
Illustration 14 g06613205
Sealed mechanical splice
Select appropriate splice size.
Strip wire 7.5 mm (0.3 inch).
Insert stripped wire into sealed mechanical splice.
Crimp sealed mechanical splice.
Apply heat to the crimped splice until tubing re-covers and adhesive flows.
Refer to "Procedure to Change Connector Plug Assembly Pins" for the proper method to reinstall ECM connector