101803-1680 ZEXEL 9 400 616 210 BOSCH INJECTION-PUMP ASSEMBLY 9400616210 1018031680 me069081

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 210 9400616210

ZEXEL 101803-1680 1018031680

MITSUBISHI ME069081 me069081

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Buy INJECTION-PUMP ASSEMBLY 101803-1680 zexel genuine, new aftermarket engine parts with delivery

Service parts 101803-1680 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101080-0860

3. GOVERNOR 105412-1940

4. SUPPLY PUMP 105210-4150

5. AUTOM. ADVANCE MECHANIS 105634-0130

6. COUPLING PLATE 105663-0260

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4761

11. Nozzle and Holder 31261-30020

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105031-3522

14. NOZZLE

105015-4370

15. NOZZLE SET

Include in #1:

101606-1240 as _

101803-1680 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 210 9400616210

ZEXEL 101803-1680 1018031680

MITSUBISHI ME069081 me069081

Zexel num

Bosch num

Firm num

Name

101803-1680

9 400 616 210

ME069081 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC8 K 14BH INJECTION PUMP ASSY PE8AD 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 opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-2-7-3- 4-5-6-8

Pre-stroke mm 4.5 4.45 4.55

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 7.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 97.2 93.7 100.7

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.3+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 18 15.4 20.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 800

Advance angle deg. 1.6 1.1 2.1

Timer adjustment_04

Pump speed r/min 1100

Advance angle deg. 4 3.5 4.5

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 6.5 6.5 6.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)The torque control spring does not operate. (3)RACK LIMIT not operating. (4)Idle sub spring setting: L1. (5)Torque spring does not operate. (6)At shipping (7)Rack difference between N = N1 and N = N2
----------
K=18 L1=6+-0.1mm N1=900r/min N2=500r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)At shipping (2)Pump speed = aa
----------
aa=900r/min
----------
a=28deg+-5deg b=32deg+-3deg c=16deg+-5deg d=(2deg) e=7deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=19deg+-5deg b=46deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)

Information:

Table 3
Injector Resistance Measurement
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Turn the keyswitch to the OFF position. Allow 2 minutes to elapse before proceeding.
2 Disconnect the DEF injector from the applicable harness.
3 Inspect the connector for damage or debris (if damaged take photo)
4 Measure the temperature of the injector (aluminum body) C
5 Connect two 398-4987 connectors to the DEF injector. The connectors must be used to prevent damage to the DEF injector connector.
6 Measure the resistance of the DEF injector. Ohms
Table 4
Dosing Accuracy Test
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Follow the Testing and Adjusting, Aftertreatment SCR System Dosing - Test.
2 Remove the injector from the DPF outlet.
3 Take a photograph of the DEF injector mount on the DPF outlet and the tip of the DEF injector.
4 Install the injector on the beaker.
5 Run the DEF System Dosing Accuracy test through Cat ET.
6 Use the breaker to measure the amount of fluid from the dosing test. ml
7 Repeat the test to verify consistency. ml
8 Install the injector back onto the DPF outlet.
Illustration 2 g06068068
DEF Injector Resistance Measurement
Illustration 3 g06067706
Injector Mount on DPF (Outlet Sample Picture)
Illustration 4 g06067753
DEF Injector Tip (Sample Picture)
When troubleshooting requests the DEF quality check, DEF injector resistance measurement or Dosing Accuracy Test, please document results in the Tables shown above.
After completing troubleshooting and performing the Aftertreatment System Functional Test, download a new Product Status Report with all ECM's.
Table 5
Injector Failure Report
Step Instruction Completed
(Yes/No) Results
Comments Units
1 Download "Product Status Report" (PSR) from the engine ECM and send to the email address in the instructions.
2 Download "Warranty Report" (WR) from the engine ECM and send to the email address in the instructions.
3 Take a picture of the injector part number / serial number.
4 Follow the correct TSG based on Table 1 and complete tables 2 through 4 when they apply.
5 Perform an "Aftertreatment System Functional Test".
6 Download "Product Status Report" (PSR) from the engine ECM and send to the email address in the instructions.
7 Submit "TIB Check List", "Product Status Reports", DEF injector deposits photographs, CEM deposit photographs, and DEF injector part number and serial number photograph to the email address in the instructions.
Fill out the Injector Failure Report and send all information including product status reports, warranty reports, DEF injector and mount photos, DEF injector part number and serial number and test results to the email address provided above.