101608-1900 ZEXEL 9 400 615 828 BOSCH INJECTION-PUMP ASSEMBLY 9400615828 1016081900 me170440

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 828 9400615828

ZEXEL 101608-1900 1016081900

MITSUBISHI ME170440 me170440

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101402-8331 as _

Cross reference number

BOSCH 9 400 615 828 9400615828

ZEXEL 101608-1900 1016081900

MITSUBISHI ME170440 me170440

Zexel num

Bosch num

Firm num

Name

101608-1900

9 400 615 828

ME170440 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D17-2 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 131424-8420

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 11.9

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 81.5 79.1 83.9

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. 10.8 9.2 12.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.9)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 81.5 80.5 82.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 88 84 92

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 59.5 55.5 63.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 85 105

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1 0.5 1.5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 1 0.5 1.5

Timer adjustment_05

Pump speed r/min 1400

Advance angle deg. 7 6.5 7.5

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)RACK LIMIT (4)Set using the changeover lever.
----------
T1=L13
----------

Speed control lever angle

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

----------
a=10deg+-5deg b=(47.5deg)+-3deg

Stop lever angle

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). (3)Rack position = approximately ee (speed lever full, speed = ff). (4)Free (at delivery) (5)Normal use set at engine manufacturer.
----------
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

0000001201

I:Idle F:At operation, hold it in the full speed position. (1)At rack position aa and pump speed bb, set the stopper bolt. (After setting it, apply red paint.) (2)Actual measurement
----------
aa=9.9+-0.1mm bb=1575r/min
----------
a=15deg+-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=7deg
----------
a=(4deg)

Information:

* For the frequency and timing of cleaning, refer to the relevant instruction manual. More frequent cleaning than necessary could damage the element or cause dust and foreign matter to be sucked into the engine.* Do not strike the element or hit it against another object to remove dust.* Do not blow compressed air against outside surfaces of the element.
Inspection Procedure Inspection: Outer Element* Shine some electric light inside the element.* Replace the element if thin spots or broken parts are evident in the filter paper, or if the packing at the top of the element is damaged. Also replace the element if the dust on the element is damp with oily smoke or soot, regardless of the replacement schedule. Inspection: Operation of dust indicator under specific negative pressure * Perform the following inspection and, if faulty, replace the dust indicator.* With no vacuum applied to the dust indicator, take measurement between the terminals 1 and 2. There should be no continuity.* Gradually apply vacuum to the dust indicator. Measure the vacuum when the continuity is made between the terminals 1 and 2.Turbocharger
Removal Sequence1 Turbocharger coupler2 Gasket3 Turbocharger insulator B4 Turbocharger insulator A5 Oil return pipe6 Gasket7 Eyebolt8 Oil pipe9 Turbocharger (See later sections.)10 Gasket*a: Exhaust manifoldX: Non-reusable parts Installation SequenceFollow the removal sequence in reverse.Tightening torque (Unit: N m {kgf m} Lubricant and/or sealant Installation Procedure Installation: Turbocharger* When installing the turbocharger, pour an appropriate amount of engine oil from the oil port so that each part operates smoothly.Turbocharger Disassembly Sequence1 Hose2 Actuator3 Coupling4 Turbine housing5 Snap ring6 Compressor cover7 O-ring8 Cartridge assemblyX: Non-resusable parts Assembly SequenceFollow the disassembly sequence in reverse.Service standards (Unit: mm) Tightening torque (Unit: N m {kgf m} Lubricant and/or sealant Work Before Removal Mating Marks* Draw a line across the coupling, turbine housing, compressor cover, and cartridge assembly. This line will serve as mating marks in the installation procedure. Removal Procedure Removal: Turbine housing
* Tap all around the end of the turbine housing with a rubber hammer or a similar tool, being careful not to damage the turbine housing.* Do not let the blades of the cartridge assembly hit the turbine housing, as they are easily bent.
Removal: Compressor Cover
* Tap all around the end of the turbine housing with a rubber hammer or a similar tool, being careful not damage the turbine housing.* Do not let the blades of the cartridge assembly hit the turbine housing, as they are easily bent.
Work after Disassembly Cleaning* Before cleaning the parts, carry out a visual inspection for any marks of burns or wear that may become difficult to find after the cleaning. If any defects are evident, replace the part(s).* Immerse the disassembled parts in an inflammable solvent (a 5 to 10 aqueous solution of Oil Clean from New Hope Co., Ltd.). Take out the parts from the solvent and dry them with compressed air. If there is any solid matter remaining on the parts, remove them with a plastic scraper or a bristle brush.
*