101607-6342 ZEXEL 9 400 615 693 BOSCH INJECTION-PUMP ASSEMBLY 9400615693 1016076342 me076396


 

Information injection-pump assembly

BOSCH 9 400 615 693 9400615693
ZEXEL 101607-6342 1016076342
MITSUBISHI ME076396 me076396
101607-6342 INJECTION-PUMP ASSEMBLY
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Service parts 101607-6342 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-8471
3. GOVERNOR 105931-9731
4. SUPPLY PUMP 105210-4661
5. AUTOM. ADVANCE MECHANIS 105672-5180
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:

101607-6342 as INJECTION-PUMP ASSEMBLY

Include in #2:

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

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   1150--
Advance angle deg.   0 0 0
Remarks
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
 

Test data Ex:

Governor adjustment

Test data 101607-6342
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
----------

Speed control lever angle

Test data 101607-6342
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

Stop lever angle

Test data 101607-6342
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)

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
----------

Timing setting

Test data 101607-6342
(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)




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

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