101608-6462 ZEXEL F 019 Z20 024 BOSCH INJECTION-PUMP ASSEMBLY f019z20024 1016086462 me441276

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 024 f019z20024

ZEXEL 101608-6462 1016086462

MITSUBISHI ME441276 me441276

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104749-0820 as _

Cross reference number

BOSCH F 019 Z20 024 f019z20024

ZEXEL 101608-6462 1016086462

MITSUBISHI ME441276 me441276

Zexel num

Bosch num

Firm num

Name

101608-6462

F 019 Z20 024

ME441276 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D16TL K 14BN INJECTION PUMP ASSY 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 131424-5520

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 4.5 4.45 4.55

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 A

Rack position 11.1

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 103.5 102.5 104.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 54.7 54.7

Boost pressure mmHg 410 410

Injection quantity adjustment_02

Adjusting point -

Rack position 9.1+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 16.5 15 18

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point E

Rack position 11.3++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 145 145 155

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position 9.65

Boost pressure kPa 16 13.3 18.7

Boost pressure mmHg 120 100 140

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position 10.7

Boost pressure kPa 41.3 34.6 48

Boost pressure mmHg 310 260 360

Timer adjustment

Pump speed r/min 0

Advance angle deg. 3 2.5 3.5

Load 0/4

Timer adjustment_02

Pump speed r/min 550+50

Advance angle deg. 3 2.5 3.5

Load 0/4

Remarks
Start

Timer adjustment_03

Pump speed r/min 650-50

Advance angle deg. 0 0 0

Load 0/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL (5)Set idle sub-spring (6)Main spring setting
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K=14 BCL=1.05+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(12.5deg)+-5deg b=(26.5deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Pump speed aa and rack position bb (to be sealed at delivery)
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aa=0r/min bb=4-0.5mm
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a=28deg+-5deg b=(48deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A) After adjusting the boost compensator, tighten the bolts to remove the heads. (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
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T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
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Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=6deg
----------
a=(3deg)

Information:

(5) Removing Alternator
(a) Disconnect the battery cables.(b) Disconnect the lead from terminal B at the rear of the alternator.(c) Remove the alternator connector.(d) Loose the alternator adjusting bolt (1) and support bolt (2), then push the alternator toward the engine and remove the fan belt.(e) Remove the alternator.
Removing alternator(6) Removing Starter
(a) Disconnect the battery's (-) and (+) terminals in that sequence.(b) Disconnect the starter wiring (1).(c) Remove the starter's two mounting bolts (2), then remove the starter (3).
Removing starter(7) Removing Oil Filter
(a) The oil filter (2) must be replaced every 100 hours of use.(b) Remove the oil filter using a filter wrench (1).
Removing oil filter(8) Removing Fuel Filter
(a) Remove the fuel hose (1) that leads to the fuel injection pump.(b) Remove the fuel filter (2) from the engine.
Removing fuel filter(9) Removing Fuel Pipes
(a) Remove the clamps from the four fuel pipes (1), then disconnect the fuel pipes from the engine and from the injection pump.(b) Remove the lock nuts (2) and the fuel leak-off pipe (3) from the injection nozzle.
Removing Fuel Pipes
To keep dirt out of the fuel system, fit rubber caps over the parts of the injection pump and injector inlet connectors from which the injection pipes are disconnected.
(10) Removing Injection Pump
Removing Injection Pump(1) Fuel hose(2) Fuel pipe(3) Tie rod cover(4) Tie rod spring(5) Tie rod(6) Injection pump(7) Adjustment shim(8) Control rack pin(a) Remove the tie rod cover (3).(b) Using long-nosed pliers, remove the tie rod spring (4) from the control rack pin (8) and from the governor lever pin.(c) Remove the tie rod (5).
Removing tie rod(d) Remove the injection pump (6) and the adjustment shim (7).
Removing injection pump(11) Removing ETS Solenoid
Loose the nut (1) and remove the ETS solenoid (2).
Removing ETS solenoid(12) Removing Oil Pump
Remove the oil pump's four mounting bolts, then remove the oil pump (1).
Removing oil pump(13) Removing Injection Nozzle
(a) Remove all lock nuts (1) (4 pieces).(b) Remove fuel leak-off pipe (2) and fuel return gasket (3).(c) Remove fuel injection nozzle (4) and holder gasket (5).
Removing injection nozzleRefitting Accessories
General Points
Refit accessories by following the removal procedures in reverse. After refitting accessories, perform the following:(1) Pour the specified amount of engine oil into the engine.(2) Pour coolant into the coolant system.(3) To facilitate starting, pour engine oil into the governor's hydraulic oil filter via the hole of the air bleeding plug.(4) Make sure no oil or coolant is leaking from joints and connections.(5) Air-bleed the fuel system.(6) After refitting the injection pump (see the instructions below), be sure to inspect and adjust the injection timing.Installing Injection Pump
Installation should be performed basically by following the removal procedure in reverse. The following operations must also be performed.(1) Bleeding Air from Fuel System
Bleeding air from fuel system(a) Feed fuel to the engine by turning the key to the ON position. Then, loosen the air vent screw (1), allow air in the filter to be expelled, and retighten the screw.(b) Loosen air vent screws (2) and (3) on the injection pump in that sequence to bleed air from the