Information injection-pump assembly
BOSCH
9 400 615 693
9400615693
ZEXEL
101607-6342
1016076342
MITSUBISHI
ME076396
me076396

Rating:
Service parts 101607-6342 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076952
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Include in #1:
101607-6342
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-6831
as _
Cross reference number
BOSCH
9 400 615 693
9400615693
ZEXEL
101607-6342
1016076342
MITSUBISHI
ME076396
me076396
Zexel num
Bosch num
Firm num
Name
101607-6342
9 400 615 693
ME076396 MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D17 K
6D17 K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
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
1150--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
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=G43
----------
----------
T1=G43
----------
Speed control lever angle

F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=(42deg)+-3deg
----------
aa=35mm
----------
a=33deg+-5deg b=(42deg)+-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 (speed lever full, speed = ff).
(4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm ff=0r/min
----------
a=13deg+-5deg b=0deg+-5deg c=(25deg)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm ff=0r/min
----------
a=13deg+-5deg b=0deg+-5deg c=(25deg)
0000001501 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=400r/min Ra=9.2+-0.1mm
----------
----------
N1=400r/min Ra=9.2+-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=(1deg)
----------
aa=10deg
----------
a=(1deg)
Information:
C3.8 DPF
Illustration 14 g06047943
When the pin gauge is inserted into the cell hole, insert the gauge by lightly tapping on the pin with your finger tip. If the pin is pushed in by force, the pin can pierce through the ash and there would not be an accurate measurement.
After the DPF filter is cleaned, measure the depth of ash (depth of remaining ash) in 21 locations with a pin gauge of 0.5 mm to 1.0 mm in diameter, which is slightly less than the cell width at the positions.The minimum remaining ash depth is 106 mm (4.2 inch).The maximum depth is 140 mm (5.5 inch).
Table 2
Measurement Locations 21 Places
A 57 mm (2.2 inch)
B 57 mm (2.2 inch)
C 10 mm (0.4 inch)
D 35 mm (1.4 inch)
E 138 mm (5.4 inch)
F 35 mm (1.4 inch)
G 226 mm (8.9 inch)
If the depth of ash is out of the permissible range, the DPF filter cannot be reused. Replace the DPF filter with a new one.C3.3B DPF
Illustration 15 g03617080
When the pin gauge is inserted into the cell hole, insert the gauge by lightly tapping on the pin with your finger tip. If the pin is pushed in by force, the pin can pierce through the ash and there would not be an accurate measurement.
After the DPF filter is cleaned, measure the depth of ash (depth of remaining ash) in 25 locations with a pin gauge of 0.6 mm to 0.8 mm in diameter.C3.8 & C3.3B Engines - The minimum remaining ash depth is 119 mm (4.7 inch).
If the depth of ash is out of the permissible range, the DPF filter cannot be reused. Replace the DPF filter with a new one.C2.4 DPF
Illustration 16 g06047315
After the DPF filter is cleaned, measure the depth of ash (depth of remaining ash) in 16 locations with a pin gauge of 0.6 mm to 0.8 mm in diameter.C2.4 Engines (Naturally Aspirated) - The minimum remaining ash depth is 102 mm (4.0 inch).C2.4 Engines (Turbo) - The minimum remaining ash depth is 119 mm (4.7 inch).
If the depth of ash is out of the permissible range, the DPF filter cannot be reused. Replace the DPF filter with a new one.Assembly of the DPF Canister
Refer to the Disassembly and Assembly Manual, Diesel Particulate Filter - Assemble for the procedure to disassemble the DPF.
Illustration 17 g06047871
(14) Gas flow
Assemble the DPF filter in the right direction by referring to the arrow (14) on the side showing the flow of exhaust gas.
When installing the temperature sensor and differential pressure pipe, apply 4C-5599 Anti-Seize Compound to the threads.Note: Itis recommended to replacethe two differential pressure hoses.
If the engine is installed in the machine, refer to the machines Engine Supplement, Diesel Particulate Filter - Remove and Install for the procedure to install the DPF.Soot Load
The soot load reset should only be performed after the DPF is cleaned or a new DPF is installed. If the Soot Load Reset is performed any other times, soot load could cause the DPF to crack
Illustration 14 g06047943
When the pin gauge is inserted into the cell hole, insert the gauge by lightly tapping on the pin with your finger tip. If the pin is pushed in by force, the pin can pierce through the ash and there would not be an accurate measurement.
After the DPF filter is cleaned, measure the depth of ash (depth of remaining ash) in 21 locations with a pin gauge of 0.5 mm to 1.0 mm in diameter, which is slightly less than the cell width at the positions.The minimum remaining ash depth is 106 mm (4.2 inch).The maximum depth is 140 mm (5.5 inch).
Table 2
Measurement Locations 21 Places
A 57 mm (2.2 inch)
B 57 mm (2.2 inch)
C 10 mm (0.4 inch)
D 35 mm (1.4 inch)
E 138 mm (5.4 inch)
F 35 mm (1.4 inch)
G 226 mm (8.9 inch)
If the depth of ash is out of the permissible range, the DPF filter cannot be reused. Replace the DPF filter with a new one.C3.3B DPF
Illustration 15 g03617080
When the pin gauge is inserted into the cell hole, insert the gauge by lightly tapping on the pin with your finger tip. If the pin is pushed in by force, the pin can pierce through the ash and there would not be an accurate measurement.
After the DPF filter is cleaned, measure the depth of ash (depth of remaining ash) in 25 locations with a pin gauge of 0.6 mm to 0.8 mm in diameter.C3.8 & C3.3B Engines - The minimum remaining ash depth is 119 mm (4.7 inch).
If the depth of ash is out of the permissible range, the DPF filter cannot be reused. Replace the DPF filter with a new one.C2.4 DPF
Illustration 16 g06047315
After the DPF filter is cleaned, measure the depth of ash (depth of remaining ash) in 16 locations with a pin gauge of 0.6 mm to 0.8 mm in diameter.C2.4 Engines (Naturally Aspirated) - The minimum remaining ash depth is 102 mm (4.0 inch).C2.4 Engines (Turbo) - The minimum remaining ash depth is 119 mm (4.7 inch).
If the depth of ash is out of the permissible range, the DPF filter cannot be reused. Replace the DPF filter with a new one.Assembly of the DPF Canister
Refer to the Disassembly and Assembly Manual, Diesel Particulate Filter - Assemble for the procedure to disassemble the DPF.
Illustration 17 g06047871
(14) Gas flow
Assemble the DPF filter in the right direction by referring to the arrow (14) on the side showing the flow of exhaust gas.
When installing the temperature sensor and differential pressure pipe, apply 4C-5599 Anti-Seize Compound to the threads.Note: Itis recommended to replacethe two differential pressure hoses.
If the engine is installed in the machine, refer to the machines Engine Supplement, Diesel Particulate Filter - Remove and Install for the procedure to install the DPF.Soot Load
The soot load reset should only be performed after the DPF is cleaned or a new DPF is installed. If the Soot Load Reset is performed any other times, soot load could cause the DPF to crack
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Mitsubishi
Mitsubishi
101607-6342
9 400 615 693
ME076396
INJECTION-PUMP ASSEMBLY
6D17
6D17