101607-6312 ZEXEL 9 400 615 691 BOSCH INJECTION-PUMP ASSEMBLY 9400615691 1016076312 me076360

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 691 9400615691

ZEXEL 101607-6312 1016076312

MITSUBISHI ME076360 me076360

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104746-6820 as _

Cross reference number

BOSCH 9 400 615 691 9400615691

ZEXEL 101607-6312 1016076312

MITSUBISHI ME076360 me076360

Zexel num

Bosch num

Firm num

Name

101607-6312

9 400 615 691

ME076360 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D16 K

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 11.7

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 77.4 75.1 79.7

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 800 800 800

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(11.7)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77.4 76.4 78.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.55

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 87.7 83.7 91.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 56 52 60

Fixing the lever *

Injection quantity adjustment_06

Adjusting point E

Rack position (R1+0.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 87.6 83.6 91.6

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 91 81 101

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1080

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 2.5 2.5 2.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min 1390

Advance angle deg. 6 5.5 6.5

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
----------
T1=H51
----------

Speed control lever angle

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

----------
a=24deg+-5deg b=(46deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use 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. (4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg

0000001501 LEVER

(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=(46deg)+-3deg c=24deg+-5deg

0000001601 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------

0000001701 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=1630r/min Ra=8.8+-0.1mm
----------

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=10deg
----------
a=(3deg)

Information:

Safety Precautions
Make sure that you disconnect all power to the monitor before performing any of the procedures that follow.
Disconnect all electrical power from the monitor before removing components. Failure to disconnect the power could result in severe electrical shock or damage to the monitor. An electrical shock can cause severe personal injury or death.
Removing The Flat Panel Display
The monitor has 10 screws that secure the flat panel display to the chassis.In order to remove the flat panel display, perform the following procedure:
Remove the top cover of the monitor. Refer to Testing and Adjusting, "Cover - Remove" for details on removing the top cover.
Illustration 1 g00858319
Central Processing Unit (CPU) Card (1) Display Connector
Disconnect the video cable that is connected to the display connector (1) on the CPU card.
Illustration 2 g00858320
(2) Power Supply (3) Touchscreen Controller Board (4) Pin 1 on the touchscreen cable connector
If the unit is equipped with a touchscreen, remove the back cover of the monitor. Refer to Testing and Adjusting, "Cover - Remove" for details on removing the back cover.Disconnect the touchscreen cable (flexible cable) from the touchscreen controller board (3). The touchscreen controller board (3) is attached to the outside of the power supply (2) .
Illustration 3 g00858321
10 Screws
Remove the 10 screws that secure the flat panel display to the chassis of the monitor.
Illustration 4 g00858322
(5) Video Cable (6) Backlight Power Supply (7) Indicator Board (8) Backlight TubesNote: This illustration shows the 264 mm (10.4 inch) version. The backlight power supply board (6) on the 307 mm (12.1 inch) version is mounted on a separate detachable bracket. The backlight power supply board is not mounted on the back of the display.
Carefully pull the flat panel display away from the chassis and disconnect the following connectors from the flat panel display:
Indicator connector from the indicator board (7)
Power cable that is attached to the backlight power supply (6) Replacing The Backlight Tubes
The backlight assembly contains two backlight tubes (8), which must be replaced. The replacement tubes are 203-7814 Boards .In order to replace the backlight tubes (8), perform the following procedure:
Disconnect the backlight tube connectors from the backlight power supply (6) .
Remove the two screws that are holding each backlight tube (8) in place.
Slide the tube to the left and gently pull the tube out of the assembly.
Insert the replacement backlight tube into the slot. Slide the tube to the right until the holes for the screws are aligned. Replace the screws.
Reattach the backlight tube connectors to the backlight power supply (6) .
Reattach the indicator connector to the indicator board (7) and the power cable to the backlight controller board.
Reattach the display cable to the CPU card. Attach the touchscreen cable to the touchscreen controller board (3) .
Reattach the display assembly to the unit. Use the 10 screws.
Replace the top cover of the unit. Replace the back cover of the unit.