Information injection-pump assembly
BOSCH
9 400 610 746
9400610746
ZEXEL
101608-1054
1016081054
MITSUBISHI
ME075811
me075811
Rating:
Service parts 101608-1054 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME075788
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Cross reference number
BOSCH
9 400 610 746
9400610746
ZEXEL
101608-1054
1016081054
MITSUBISHI
ME075811
me075811
Zexel num
Bosch num
Firm num
Name
101608-1054
9 400 610 746
ME075811 MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D16 K
6D16 K
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
131424-8420
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
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
3.2
3.15
3.25
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
11.7
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
78
75.7
80.3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
10+-0.5
Pump speed
r/min
480
480
480
Each cylinder's injection qty
mm3/st.
21.8
18.5
25.1
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.7)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
78
77
79
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.25
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
82.5
78.5
86.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.55
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
51.5
47.5
55.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
115
115
135
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1150--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
5
4.5
5.5
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=M12
----------
----------
T1=M12
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=21deg+-5deg b=38deg+-3deg
----------
aa=40mm
----------
a=21deg+-5deg b=38deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
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 and rack position = dd.
(3)R = approximately ee (speed lever full, speed = ff)
(4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm ff=0r/min
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm ff=0r/min
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg
0000001501 LEVER
(A) Idle
(B) Full speed
(C) Base lever
(D) Accelerator lever
(E) Accelerator lever delivery position
1. Measure speed lever angle
(1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------
----------
b=38deg+-3deg c=21deg+-5deg
----------
----------
b=38deg+-3deg c=21deg+-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=8deg
----------
a=(3deg)
----------
aa=8deg
----------
a=(3deg)
Information:
Illustration 7 g06347860
Injector male spade terminals
There are two options to build injector adapter harness for C3.3.If available, use the injector connector removed from C3.3 harness. Cut both 100 mm wires from the connector and attach bullet terminals that fit in the injector adapter harness C3.8 terminal from injector test kit.If no harness is available, build a harness with the following. Two female spade terminals for injector male spade terminal, two 16 gauge 100 mm wires, and two bullet terminals for injector adapter harness C3.8 terminal.
Illustration 8 g06345429
Injector adapter harness C2.4
Illustration 9 g06346223
Injector adapter harness C3.8
Illustration 10 g06346237
Injector male spade terminals
There are two options to build injector adapter harness for C2.4.If available, use the injector connector removed from C2.4 harness. Cut both 100 mm wires from the connector and attach bullet terminals that fit in the injector adapter harness C3.8 terminal from injector test kit.If no harness is available, build a harness with the following. Two female spade terminals for injector male spade terminal, two 16 gauge 100 mm wires, and two bullet terminals for injector adapter harness C3.8 terminal.Injector Test Set-up
Illustration 11 g06346391
Mounted nozzle test group
Find a suitable stable and surface to either mount or place the nozzle test group. Fill fuel container with #1 diesel and install high-pressure hose assembly. Use adaptors, if needed, based on nozzle tester. Tighten the fuel line adapter to (25 ft lbs). Install the fuel line adapter and tighten to (25 ft lbs) to allow connection to the injector.
Illustration 12 g06346423
Injector holder assembly
Take the injector test kit and remove all parts to assemble, as shown above. Take the injector holder and the clear fuel shield with screws from the kit and remove the screws using a 3mm alan wrench. Assemble the parts so the clear fuel shield with screws is on the bottom. While, the mounted injector holder is on top with the screws removed from before.
Illustration 13 g06346719
Fuel collector and injector holder
Place injector holder onto a fuel collector or another container to capture the injection spray.
Illustration 14 g06346839
Injector setup and harness connection
Install the injector that is needing to be tested into the opening at the top of injector holder. Attach the return fuel drain hose and run the drain hose to another fuel collector. Make the harness connection using the correct adapter for the C2.4, C3.3, and C3.8 engines. Connect the injector pulse tool and the injector adapter harness to the injector.
Illustration 15 g06346868
Complete setup of nozzle tester and injector test kit
Once injector test kit and nozzle test group are set up, connect fuel line adaptor on the high-pressure hose assembly to the injector, leave connection loose. Actuate the lever on the nozzle test group until fuel drips from connection allowing air to purge from setup. Tighten fuel line adaptor at injector to (25 ft lbs).Injector Test Procedure
Illustration 16 g06346881
Mounted nozzle test group (close-up)
Inspect the injector for any leaks. Using the lever on the nozzle tester group, build injection fuel pressure to (5000 psi). Turn the locking valve to insure there is no leakage back through the tester.
Let the nozzle test
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Mitsubishi
101608-1054
9 400 610 746
ME075811
INJECTION-PUMP ASSEMBLY
6D16
6D16