Information injection-pump assembly
BOSCH
9 400 615 521
9400615521
ZEXEL
101606-6550
1016066550
MITSUBISHI
ME076491
me076491
Rating:
Service parts 101606-6550 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076465
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 615 521
9400615521
ZEXEL
101606-6550
1016066550
MITSUBISHI
ME076491
me076491
Zexel num
Bosch num
Firm num
Name
9 400 615 521
ME076491 MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D16 * K 14BE INJECTION PUMP ASSY PE6A PE
6D16 * K 14BE INJECTION PUMP ASSY PE6A PE
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
131424-5520
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.8
3.75
3.85
Beginning of injection position
Governor side NO.1
Governor 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
11.8
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
71.3
69.2
73.4
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
285
285
285
Each cylinder's injection qty
mm3/st.
11.9
10.1
13.7
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.8)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
71.3
70.3
72.3
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(11.8)
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
80.9
76.9
84.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
D
Rack position
R1+0.65
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
70.4
66.4
74.4
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
F
Rack position
R1+1.25
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
69.5
65.5
73.5
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
14.3+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
108
88
128
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1100
Advance angle
deg.
0.5
Load
3/4
Timer adjustment_02
Pump speed
r/min
1150
Advance angle
deg.
0.5
Load
4/4
Timer adjustment_03
Pump speed
r/min
1250
Advance angle
deg.
2.5
2
3
Load
4/4
Timer adjustment_04
Pump speed
r/min
1350
Advance angle
deg.
5
4.5
5.5
Load
4/4
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=D91
----------
----------
T1=D91
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=41deg+-5deg b=(37.5deg)+-3deg
----------
aa=35mm
----------
a=41deg+-5deg b=(37.5deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection.
(2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=1400r/min bb=7.2-0.5mm cc=275r/min dd=(8.5)-0.5mm
----------
a=32.5deg+-5deg b=27deg+-5deg
----------
aa=1400r/min bb=7.2-0.5mm cc=275r/min dd=(8.5)-0.5mm
----------
a=32.5deg+-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=9.6+-0.1mm
----------
----------
N1=400r/min Ra=9.6+-0.1mm
----------
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=(1deg)
----------
aa=12deg
----------
a=(1deg)
Information:
(1) End play for shaft (new) ... 0.100 0.018 mm (.0039 .0007 in)Maximum permissible end play (worn) ... 0.20 mm (.008 in)(2) Thickness of thrust bearing (where thrust rings contact bearing) ... 5.372 0.013 mm (.2115 .0005 in)(3) Tighten both band clamps with procedure that follows:a. Tighten to ... 10.2 0.7 N m (90 6 lb in)b. Tap (hit) clamp lightly all around.c. Tighten again to ... 10.2 0.7 N m (90 6 lb in)
Do not overtighten the clamps.
(4) Diameter of shaft (new) ... 11.570 to 11.577 mm (.4555 to .4558 in)Bore in the bearing (new) ... 11.608 to 11.618 mm (.4570 to .4574 in)Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)(5) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)(6) Install the compressor wheel (at room temperature) as follows:a. Put compressor wheel on the shaft.
Do not bend or add stress to the shaft when nut is loosened or tightened.
b. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut followed by application of 9S3265 Retaining Compound.c. Tighten nut to ... 24.4 1.4 N m (144 4 lb in)(7) Thickness of each thrust ring ... 2.5463 0.0064 mm (.10025 .00025 in)(8) Bore in housing (new) ... 19.050 to 19.075 mm (.7500 to .7510 in)Outside diameter of the bearing (new) ... 18.936 to 18.948 mm (.7455 to .7460 in)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 70 15 N m (50 11 lb ft) Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to provide start up lubrication and/or storage protection.
Do not overtighten the clamps.
(4) Diameter of shaft (new) ... 11.570 to 11.577 mm (.4555 to .4558 in)Bore in the bearing (new) ... 11.608 to 11.618 mm (.4570 to .4574 in)Maximum permissible clearance between bearing and shaft (worn) ... 0.05 mm (.002 in)(5) Maximum permissible gap of oil seal ring, measured in bore of housing ... 0.25 mm (.010 in)(6) Install the compressor wheel (at room temperature) as follows:a. Put compressor wheel on the shaft.
Do not bend or add stress to the shaft when nut is loosened or tightened.
b. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut followed by application of 9S3265 Retaining Compound.c. Tighten nut to ... 24.4 1.4 N m (144 4 lb in)(7) Thickness of each thrust ring ... 2.5463 0.0064 mm (.10025 .00025 in)(8) Bore in housing (new) ... 19.050 to 19.075 mm (.7500 to .7510 in)Outside diameter of the bearing (new) ... 18.936 to 18.948 mm (.7455 to .7460 in)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 70 15 N m (50 11 lb ft) Put clean engine oil in the oil inlet of the turbocharger after assembly or before installation to provide start up lubrication and/or storage protection.