101606-6002 ZEXEL 9 400 615 481 BOSCH INJECTION-PUMP ASSEMBLY 9400615481 1016066002 me076282


 

Information injection-pump assembly

BOSCH 9 400 615 481 9400615481
ZEXEL 101606-6002 1016066002
MITSUBISHI ME076282 me076282
101606-6002 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 400 615 481 9400615481
ZEXEL 101606-6002 1016066002
MITSUBISHI ME076282 me076282


Zexel num
Bosch num
Firm num
Name
101606-6002 
9 400 615 481 
ME076282  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D14T 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   3.3 3.25 3.35
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   12.5
Pump speed r/min   800 800 800
Each cylinder's injection qty mm3/st.   87.3 84.7 89.9
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(12.5)
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   87.3 86.3 88.3
Basic   *
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.75
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   85.3 81.3 89.3
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.2
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   86 82 90
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   99 79 119
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   300 300 300
Rack position   R2-0.8
Boost pressure kPa   10 10 10
Boost pressure mmHg   75 75 75
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   R2-0.6
Boost pressure kPa   13.3 12 14.6
Boost pressure mmHg   100 90 110
Boost compensator adjustment_03
Pump speed r/min   300 300 300
Rack position   R2(R1+0. 5)
Boost pressure kPa   23.3 23.3 23.3
Boost pressure mmHg   175 175 175

Test data Ex:

Governor adjustment

Test data 101606-6002
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=D17 BCL=0.8+-0.1mm
----------

Timer adjustment

Test data 101606-6002
(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C3=(8)deg t1=2--sec. t2=2--sec.
----------
N1=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=0.5--deg C2=8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

Test data 101606-6002
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=39deg+-3deg

Stop lever angle

Test data 101606-6002
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at speed = rated point and rack position = aa (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt , confirm non-injection at pump speed bb. Rack position = cc (non-injection rack position).
----------
aa=6.5-0.5mm bb=275r/min cc=(8)mm
----------
a=11.5deg+-5deg b=27deg+-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
----------

0000001601 RACK SENSOR

Test data 101606-6002
R:Rack position (mm) V:Voltage (V) After installing the rack sensor, confirm the output value (VR).
----------
N1=- Ra=R1(12.5)mm VR=1.99+-0.01V
----------

Timing setting

Test data 101606-6002
(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:


Connect the wiring harness to a voltage source of 12 VOLTS maximum with a negative ground only. Install the additive tank on the outside of the engine compartment.
Connect the wiring to 8L5000 Switch (1) so that the system can be activated with the starting motor switch in the OFF position. Keep the additive tank full when not in use. This will prevent damage to the system and components by corrosion when not used for long periods of time.Operation: Just before the engine is started, push the switch to activate the system; this will let the additive flow for approximately two minutes, through an orifice connected to the fuel supply line of the Sleeve Metering Fuel System. The fuel transfer pump then pulls the additive into the system along with the Diesel fuel. The system can be again activated if necessary. The engine can be started approximately three to four times per liter (fifteen to twenty times per gallon) of additive.Maintenance: Keep the additive tank full when not in use. This will prevent damage to the system and components by corrosion when not used for long periods of time. Install a new injection group filter (9N3778) at six month intervals or when the filter becomes plugged (full of foreign material) so additive will not flow through it. ADDITIVE RECOMMENDATION: Ethyl D112 Diesel Ignition Improver AVAILABLE SOURCE:U.S.A.
Ethyl Corporation
Distribution Service
Petroleum Chemical Division
451 Florida Boulevard
Baton Rouge, Lousiana 70801
CANADA
Ethyl Corporation of Canada, Ltd.
48 St. Clair Avenue West
Toronto, Ontario, Canada M4V1M7
Order Department
Ethyl D11-2 Diesel Ignition Improver is highly flammable; do not install the additive tank near a source of heat or sparks. If there is a leak in the tank or an accident causes a loss of additive, a fire could be the result.
1 - 9N3334 Tank Assembly2 - 1P4022 Fitting3 - 9N3778 Filter Assembly4 - 8L6557 Connector5 - 317224 Hose Assembly6 - 306984 Connector7 - 9L8791 Solenoid8 - 7W1539 Orifice9 - 8T2543 Tee10 - 5P5009 Reducer11 - 9N3828 Harness Assembly12 - 7G1018 Relay13 - 8L5000 Switch14 - 9N3335 Strap 533567 Bracket15 - 5P0733 Hose 200 (8.0")16 - 1P4278 Clamp17 - 7D1553 Clip18 - 8J1256 Clip19 - 4B1248 Screw 4B2051 Nut 4B4674 Washer20 - 3J7354 Seal21 - 1J9671 Seal1 Install items (12) and (13) inside the operator's compartment; fasten switch (13) on the dash and install relay (12) under the dash. Install additive tank (1) on the outside of the engine compartment in an acceptable location for easy access and away from any source of heat.2 Install 9N3620 Fuel Additive Injection Instruction Film on the dash next to 8L5000 Switch (13). Install 9N3621 CAUTION Film on tank (1) at a location that can be seen from the side of the vehicle.3 Install the remainder of the parts as shown in the above illustration. Fasten filter (3), and hoses (5) and (15) with the clips shown.4 Check the system for leaks after the installation is complete; use air at a maximum pressure of 70 to 105 kPa (10 to 15 psi).

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