101607-6731 ZEXEL 9 400 615 724 BOSCH INJECTION-PUMP ASSEMBLY 9400615724 1016076731 me075478

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 724 9400615724

ZEXEL 101607-6731 1016076731

MITSUBISHI ME075478 me075478

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101402-7780 as _

Cross reference number

BOSCH 9 400 615 724 9400615724

ZEXEL 101607-6731 1016076731

MITSUBISHI ME075478 me075478

Zexel num

Bosch num

Firm num

Name

101607-6731

9 400 615 724

ME075478 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 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)Accelerator lever (2)Use the hole at R = aa (3)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=24deg+-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

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=(47.5deg)+-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

Adjust the bolt to obtain the following lever position when the micro-switch is ON. 1. Microswitch adjustment (OPEN type) Confirm with the lever angle at full. (1)Speed N1 (2)Rack position Ra
----------
N1=1675r/min Ra=9.9+-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=(2deg)

Information:

Required Parts
Table 1
Required Parts List
Item Qty New Part Number Part Name Former Part Number(1)
1 1 525-3348 Plate As 461-5730
2 1 398-2993 Tank Filler Cap 398-3011
3 1 525-3357 Cover As 431-4872
4 4 9X-2038 Washer 5P-4115
5 4 8T-4138 Bolt -
6 1 246-2641 Padlock -
7 1 525-3351 (2) Guard As 461-5732
(1) The former part number listed is for reference only and may differ.
(2) For Heavy Duty(HD) rear guard assembly.Standard Rear Plate Assembly
Illustration 1 g06212425
(A) 447-5514 Film
(B) 430-3036 Film
(C) For english use 484-5902 Film and for international use 393-2614 FilmHeavy Duty Rear Guard Assembly
Illustration 2 g06212430Rework Procedure - Heavy Duty Rear Guard Assembly
Description: To adapt early heavy duty rear guard assembly (with DEF door design) for assembly with new standard rear plate assembly.Note: This rework will not provide the heavy duty shroud on the guard assembly (7) at the fill opening, that comes on the new heavy duty rear guard assembly from the factory as shown in the Illustration 2. Only the shroud on the new standard rear plate assembly (1) will be in place to protect that fill location as shown in the Illustration 2.
Illustration 3 g06213073
(D) door
(E) hinge
Remove the hinge (E) and door (D).
Illustration 4 g06212502
Cutout section with rounded corners
(F) 190 mm (7.5 inch)
(G) 40 mm (1.8 inch)
(H) 40 mm (1.8 inch)
(I) 95 mm (3.7 inch)
Illustration 5 g06212524
Cutout section with chamfered corners
(J) 55 mm (2.2 inch)
(K) 15 mm (0.6 inch)
(L) 80 mm (3.2 inch)
Cutout section from opening down by a clearance of (H) from original radius (G). The cutout should extend the entire width of opening. But corners can be significantly rounded as per dimensions shown in the Illustration 4 or chamfered as per dimensions shown in the Illustration 5. Either method is acceptable.Note: If DEF in the hydraulic tank is suspected, do not start the engine or operate the machine without first reviewing Special Instruction , M0064940 for procedure to address inadvertent adding of DEF to the machine hydraulic tank.