101607-6910 ZEXEL 9 400 615 737 BOSCH INJECTION-PUMP ASSEMBLY 9400615737 1016076910 me158010

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 737 9400615737

ZEXEL 101607-6910 1016076910

MITSUBISHI ME158010 me158010

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Service parts 101607-6910 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-2840

3. GOVERNOR 105412-2260

4. SUPPLY PUMP 105210-4150

5. AUTOM. ADVANCE MECHANIS 105614-4010

6. COUPLING PLATE 105662-0590

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6211

11. Nozzle and Holder ME059621

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

13. NOZZLE-HOLDER 105030-5010

14. NOZZLE

105015-5330

15. NOZZLE SET

Include in #1:

101607-6910 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-5130 as _

Cross reference number

BOSCH 9 400 615 737 9400615737

ZEXEL 101607-6910 1016076910

MITSUBISHI ME158010 me158010

Zexel num

Bosch num

Firm num

Name

101607-6910

9 400 615 737

ME158010 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D22C 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 131424-4620

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.5 4.45 4.55

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 A

Rack position 9.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 101 99 103

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7.6+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 17.5 14.9 20.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 800+120

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.9 0.4 1.4

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 2.5 2 3

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 4 4 5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Torque spring does not operate. (4)The torque control spring must does not have a set force. (5)Main spring setting (6)Set at delivery (7)Rack difference between N = N1 and N = N2 (8)Set idle sub-spring
----------
K=15 N1=900r/min N2=600r/min
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Set the pump speed at aa (2)At delivery (3)Set the pump speed at bb.
----------
aa=1110r/min bb=910r/min
----------
a=25deg+-5deg b=32deg+-3deg c=10deg+-5deg d=(2deg) e=7deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=43.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(7deg)

Information:

Table 1
Required Parts
Item Qty Part Number Description Former Part Number
1 1 560-4252 Bracket 431-8663
2 1 396-3862 (1) Control Harness As 396-3862 (1)
524-5527 (2) Control Harness As 524-5527 (2)
3 1 471-4176 Hose As 380-9241
4 - 7K-1181 Cable Strap NA
5 - 3E-6909 Clip NA
(1) FMC 1 - 772 (Not Equipped with DEF Quality Sensor)
(2) FMC 773 - Up (Equipped with DEF Quality Sensor)Note: These parts should be ordered and replaced only if there is evidence of damage to any part.Rework Procedure
Park the machine on level ground, lower all implements to the ground, shut off machine, and relieve all hydraulic system pressure.
Read and understand this Rework Procedure before starting work.
Illustration 1 g06340431
General location and reference Views
DEF tank cover not shown for clarity.
(A) Fuel tank
(B) Diesel Exhaust Fluid (DEF) module group
See Illustration for the general location of the DEF Module Group and reference views that will be used in future steps.
Illustration 2 g06340436
Location of hardware.
(C) Hardware
(D) DEF fill hose
(E) Clamp
Inspect control harness assembly (2) at location (AA) and hose assembly (3) at location (BB) for rubbing and or fouling on the DEF Tank Cover. If either item is damaged, replace the damaged part.Note: Hardware (C) holding the DEF Module Group to the fuel tank and clamp (E) holding DEF Fill Hose (D) to the tank will need to be loosened to reposition the DEF Module Group to access control harness assembly (2) and hose assembly (3).
After control harness assembly (2) and hose assembly (3) have been inspected and found without damage OR replaced, secure both parts using Steps 6 through 9.
Illustration 3 g06340441
Left view
Fuel tank not shown.
(F) Diesel exhaust fluid module
Illustration 4 g06340446
Location CC
(G) Harness bundled to avoid fouling
Illustration 5 g06340447
Location DD
(H) Terminating resistor
Secure control harness assembly (2) and hose assembly (3) to left side of DEF Module using tie straps (4).Reference: Refer to Illustrations 3, 4, and 5.Note: At location (CC), use tie straps to secure harness bundles to prevent harness from contacting the fuel tank. (See Illustration 4).Note: At location (DD), use tie straps (4) to secure control harness assembly (2) and hose assembly (3), and terminating resistor (H) at lower location. (See Illustration 5).
Illustration 6 g06340448
Location of hardware
(C) Hardware
(E) Clamp
Reposition the DEF Module Group, install bracket (1), and reinstall the remaining hardware (C), clamp (E) removed in Step 4. Check to make sure control harness assembly (2) and hose assembly (3) will not