101608-6483 ZEXEL F 019 Z20 025 BOSCH INJECTION-PUMP ASSEMBLY f019z20025 1016086483 me441450

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 025 f019z20025

ZEXEL 101608-6483 1016086483

MITSUBISHI ME441450 me441450

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Buy INJECTION-PUMP ASSEMBLY 101608-6483 zexel genuine, new aftermarket engine parts with delivery

Service parts 101608-6483 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6730

3. GOVERNOR 105411-2552

4. SUPPLY PUMP 105210-5451

5. AUTOM. ADVANCE MECHANIS 105680-9050

6. COUPLING PLATE 105663-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5340

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7(180)

13. NOZZLE-HOLDER 105030-3660

14. NOZZLE 105025-4020

15. NOZZLE SET

Include in #1:

101608-6483 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-0726 as _

Cross reference number

BOSCH F 019 Z20 025 f019z20025

ZEXEL 101608-6483 1016086483

MITSUBISHI ME441450 me441450

Zexel num

Bosch num

Firm num

Name

101608-6483

F 019 Z20 025

ME441450 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 11.5

Pump speed r/min 895 895 895

Average injection quantity mm3/st. 122.5 121.5 123.5

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 48.7 48.7

Boost pressure mmHg 365 365

Injection quantity adjustment_02

Adjusting point -

Rack position 8.5+-0.5

Pump speed r/min 350 350 350

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 12.4++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 120 130

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1-1.45

Boost pressure kPa 13.3 10.6 16

Boost pressure mmHg 100 80 120

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R1(11.5)

Boost pressure kPa 35.3 28.6 42

Boost pressure mmHg 265 215 315

Timer adjustment

Pump speed r/min 830--

Advance angle deg. 0 0 0

Load 4/4

Remarks
Beginning of advance.

Timer adjustment_02

Pump speed r/min 430

Advance angle deg. 3 2.5 3.5

Load 0/4

Remarks
Start

Timer adjustment_03

Pump speed r/min (550)

Advance angle deg. 0 0 0

Load 0/4

Timer adjustment_04

Pump speed r/min 780

Advance angle deg. 0.5

Load 4/4

Timer adjustment_05

Pump speed r/min 895

Advance angle deg. 0.75 0.25 1.25

Load 4/4

Timer adjustment_06

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 4/4

Remarks
Measure the actual speed, stop

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 at delivery (6)Set idle sub-spring
----------
K=5 BCL=1.45+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)When pump speed set at bb (3)Stopper bolt setting
----------
aa=905r/min bb=760r/min
----------
a=20deg+-5deg b=8deg+-5deg c=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)
----------
aa=0r/min bb=4-0.5mm
----------
a=28deg+-5deg b=(48deg)

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:

Disassembly and Reassembly of General Parts
Oil seals
When driving oil seals into place, follow the instructions below: Driving Seals into Housing:(a) Place the seal lip correctly. Make sure it is not damaged.(b) Before driving a seal into place, apply a light coat of grease to the periphery of the seal that fits into the housing.(c) Use a driving tool like the one shown in the illustration that is specifically designed for the purpose. The tool can properly guide the lip and hold evenly the top of the seal when it is tapped, so it allows the seal to be driven straight down. Do not use hammers on bare seals as seal will be damaged.
Oil seal driving tool Driving Seals onto Shaft:(a) Coat the seal lip with grease.(b) Use seal guide like the one shown in the illustration when the shaft has steps, splines, threads or keyways.
Oil seal guideO-Rings
Use a guide when it is necessary to move O-rings over steps, splines, threads or keyways to install them. Apply a light coat of grease to O-rings before fitting them.
O-ring guideBearings
(1) When driving bearing into place, be sure to tap the race that is being fitted. (If the inner race is being fitted, tap the inner race. Likewise, if it is the outer race that is being fitted, tap the outer race.)Use fitting tools like the ones in the illustration that are appropriate for inner or outer races.
Bearing fitting tool(2) Bearings are best fitted using a press as shock loads and errors can be minimized.
Fitting bearing using a pressLock Plates
Always bend lock plates properly. The illustration on the right show some of typical lock plates being bent properly and improperly.
Typical lock plates with good and bad bendsSplit Pins and Spring Pins
As a rule, all split pins must be replaced with new ones after each removal. It is also important to bend split pins properly. Spring pins must be driven into place completely.