101607-6242 ZEXEL 9 400 615 685 BOSCH INJECTION-PUMP ASSEMBLY 9400615685 1016076242 me076384

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 685 9400615685

ZEXEL 101607-6242 1016076242

MITSUBISHI ME076384 me076384

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Buy INJECTION-PUMP ASSEMBLY 101607-6242 zexel genuine, new aftermarket engine parts with delivery

Service parts 101607-6242 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8471

3. GOVERNOR 105931-9640

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105672-5190

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7053

11. Nozzle and Holder ME076953

12. Open Pre:MPa(Kqf/cm2) 15.7(160)/21.6(220)

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE 105015-9151

15. NOZZLE SET

Include in #1:

101607-6242 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-6921 as _

Cross reference number

BOSCH 9 400 615 685 9400615685

ZEXEL 101607-6242 1016076242

MITSUBISHI ME076384 me076384

Zexel num

Bosch num

Firm num

Name

101607-6242

9 400 615 685

ME076384 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D15T3 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 131424-8420

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 3.2 3.15 3.25

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 -

Rack position 12.3

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 101.8 98.7 104.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 600 600 600

Each cylinder's injection qty mm3/st. 11.5 9.8 13.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 101.8 100.8 102.8

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 117.9 113.9 121.9

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 4)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 92.6 88.6 96.6

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_06

Adjusting point E

Rack position R1+0.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 113.5 109.5 117.5

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_07

Adjusting point F

Rack position (R2-0.75 )

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 48.2 46.2 50.2

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position (R2-0.75 )

Boost pressure kPa 3.3 2 4.6

Boost pressure mmHg 25 15 35

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2(R1-0. 4)

Boost pressure kPa 22.7 22.7 22.7

Boost pressure mmHg 170 170 170

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1340

Advance angle deg. 3.5 3 4

Remarks
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)Boost compensator stroke: BCL
----------
T1=H52 BCL=(0.75)+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=42deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=1350r/min bb=7-0.5mm cc=275r/min dd=(8)mm
----------
a=25deg+-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
----------

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=11deg
----------
a=(3deg)

Information:

Specifications
The following table lists the specifications for the CPU that is used on the 203-7810 Engine Monitoring Control Group and the 203-7811 Engine Monitoring Control Group.
Table 1
Item Description
Socket 7 Processor Intel Pentium MMX 233 MHz
BIOS Phoenix OEM BIOS
256 K X 8 flash EPROM (boot ROM)
Main Memory Up to 256 Mbytes DRAM (one 168 pin DIMM socket)
60 ns 3.3 V EDO / SDRAM with ECC
60 and 66 MHz bus speeds
L2 Cache Memory 512 KB pipeline burst static RAM
Chipsets Acer M1531B North Bridge
Acer M1543B South Bridge
Video Interface Chips & Technologies CHIPS 65550
2 Mbytes VGA local memory
Internal LVDS interface to indicator panel
External HD15 CRT (analog monitor) connector
Ethernet PCI 10/100 BaseT
Intel 82559 MAC
Filtered RJ-45 connector
Other CPU I/O Two RS232 serial ports ("COM1" and "COM2") (1)
Parallel port ("LPT1")
Two PS/2 ports for keyboard and mouse connections
Two USB ports
System Hardware Monitor LM78 Monitor IC mapped to IRQ5, drives diagnostics indicator
Internal temperature via DS1620 IC
User configured via BIOS
Other Features M5819 Real Time Clock chip with 256 bytes RAM
MAX705 Watchdog Timer
( 1 ) "COM2" is used by optional touchscreen interfaceSystem Hardware Monitor
The systems hardware monitor checks the following items:
2.8 V supply (CPU core)
3.3 V supply
5 V supply
12 V supply