101607-6330 ZEXEL 9 400 615 692 BOSCH INJECTION-PUMP ASSEMBLY 9400615692 1016076330 me076424

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 692 9400615692

ZEXEL 101607-6330 1016076330

MITSUBISHI ME076424 me076424

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Service parts 101607-6330 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8391

3. GOVERNOR 105931-9690

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105672-5070

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7061

11. Nozzle and Holder ME076952

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-3030

14. NOZZLE

15. NOZZLE SET 105019-0230

Include in #1:

101607-6330 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-6821 as _

Cross reference number

BOSCH 9 400 615 692 9400615692

ZEXEL 101607-6330 1016076330

MITSUBISHI ME076424 me076424

Zexel num

Bosch num

Firm num

Name

101607-6330
101608-1100

9 400 615 692

ME076424 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D17 * K 14BF INJECTION PUMP ASSY PE6AD 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 131424-8420

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 12

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 85.1 82.5 87.7

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(12)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 85.1 84.1 86.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.85

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 99.9 95.9 103.9

Fixing the lever *

Injection quantity adjustment_05

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 1100

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 2.5 2.5 3.5

Timer adjustment_03

Pump speed r/min 1450

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=H28
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=10deg+-5deg b=(47.5deg)+-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

0000001201

F:At operation, hold it in the full speed position. I:Idle (1)At rack position aa and pump speed bb, set the stopper bolt. (After setting it, apply red paint.) (2)Actual measurement
----------
aa=9.9+-0.1mm bb=1575r/min
----------
a=15deg+-5deg

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=(2deg)

Information:

Introduction
Do not perform any of the following procedure or order parts until you have read and understand the procedure. The procedure that follows below covers that installation of the new Diesel Exhaust Fluid (DEF) filter.Required Parts
Table 1 below contain the parts needed to complete the installation of the new DEF filter.Note: Only one DEF filter group is required per engine. Use Table 2 to determine which filter is the appropriate filter for each DEF header. Illustration 1 shows the location of the DEF header part number.
Table 1
Item Qty Part Number Part Description
1 1 452-6055 Filter Base As
2 1 453-1604(1) Diesel Exhaust Fluid Filter Gp
3 1 453-1605***#i05999309/d1820e940*** Diesel Exhaust Fluid Filter Gp
4 1 453-1606***#i05999309/d1820e940*** Diesel Exhaust Fluid Filter Gp
5 1 378-3187 Diesel Exhaust Fluid Filter Gp
6 1 423-3251 Connector
7 1 425-0385 Filter As
8 1 391-5262 Gasket
(1) Use Table 2 to choose the correct part that corresponds to the DEF header
Illustration 1 g03745839
(1) Location of DEF header part number
Table 2
DEF Header Part Number Required DEF Filter
434-3241 453-1604
434-3242 453-1605
434-3243 453-1606 Installation Procedure
Illustration 2 g03736523
(1) DEF header
(2) DEF filter
(3) DEF tank
(4) DEF header bolts
Clean the area around DEF header (1). Clear any dirt or debris that could contaminate the DEF tank or lines when removed. Note: If proper cleaning is not performed, DEF pump performance issues or failure may occur.
Disconnect the two DEF lines, two coolant lines, and harness from the DEF header assembly.
Remove the six DEF header screws (4) from the DEF header assembly. Note: Do not discard the screws that secure the DEF header assembly to the DEF tank. The screws will be reused in a later step.
Remove the DEF header assembly. Remove the previous DEF header gasket and discard.
Illustration 3 g03736534
(5) 452-6055 Filter Base As
Install filter base assembly (5) onto the DEF header assembly. Note: Each half of the adapter has two small locking tabs that secure to the bottom side of the DEF header assembly.
Remove the previous 425-0385 Filter As located at the bottom of the DEF pick-up tube.
Install the new 425-0385 Filter As onto the DEF header assembly.
Illustration 4 g03736545
(6) Band clamp
Install the correct DEF filter onto the DEF header adapter and secure using band clamp (6) that is supplied. Torque the band clamp to 4.5 0.7 N m (40 6 lb in).
Install the DEF header assembly back into the DEF tank. Secure the DEF header to the DEF tank using the six screws previously removed in Step 3. Torque the six screws to 5 1 N m (44 9 lb in).
Reconnect the harness, coolant lines, and DEF lines to the DEF header.
Illustration 5 g03736566
(7) DEF pump inlet filter fitting
(8) Main DEF pump filter
Replace DEF pump inlet filter fitting (7) and main DEF pump filter (8). Refer to Disassembly and Assembly, UENR0132, "Diesel Exhaust Fluid Filter - Remove and Install" for the replacement procedure.