101608-6402 ZEXEL 9 400 619 940 BOSCH INJECTION-PUMP ASSEMBLY 9400619940 1016086402 me441213


101608-6402 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 940 9400619940
ZEXEL 101608-6402 1016086402
MITSUBISHI ME441213 me441213

Service parts 101608-6402 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6800
3. GOVERNOR 105411-2462
4. SUPPLY PUMP 105210-5451
5. AUTOM. ADVANCE MECHANIS 105680-9030
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105160-5190
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 17.7(180)
13. NOZZLE-HOLDER 105030-3660
14. NOZZLE 105025-3250
15. NOZZLE SET

Include in #1:

101608-6402 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 619 940 9400619940
ZEXEL 101608-6402 1016086402
MITSUBISHI ME441213 me441213


Zexel num
Bosch num
Firm num
Name
101608-6402 
9 400 619 940 
ME441213  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
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   109.5 108.5 110.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the lever   *
Boost pressure kPa   62.7 62.7
Boost pressure mmHg   470 470
Injection quantity adjustment_02
Adjusting point   -
Rack position   8+-0.5
Pump speed r/min   400 400 400
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   11.2++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   95 95 105
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   375 375 375
Rack position   9.2
Boost pressure kPa   10.7 4 17.4
Boost pressure mmHg   80 30 130
Boost compensator adjustment_02
Pump speed r/min   375 375 375
Rack position   10.45
Boost pressure kPa   56 50.6 56
Boost pressure mmHg   420 380 420
Timer adjustment
Pump speed r/min   600
Advance angle deg.   3 2.5 3.5
Load   0/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   720
Advance angle deg.   0.5
Load   0/4
Timer adjustment_03
Pump speed r/min   (850)
Advance angle deg.   0 0 0
Load   4/4
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   1075
Advance angle deg.   1.5 1 2
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101608-6402
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
----------
K=10 BCL=1.25+-0.1mm
----------

Speed control lever angle

Test data 101608-6402
F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=0deg+-5deg b=18deg+-5deg

Stop lever angle

Test data 101608-6402
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)

0000001501 RACK SENSOR

Test data 101608-6402
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Mount the joint (B). (2)Select the shim (D) so that the rack limit's rack position is obtained at that time. (3)Install the rod (E) to the block (C). The distance between the pump end face and the rod (E) at rack limit must be L. 2. Rack sensor adjustment (-0020) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set at speed N. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (6)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
L=38-0.2mm N=1000r/min Ra=11mm
----------

0000001601 TAMPER PROOF

Test data 101608-6402
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)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

Timing setting

Test data 101608-6402
(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=8deg
----------
a=(3deg)




Have questions with 101608-6402?





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