106676-2490 ZEXEL 9 400 617 449 BOSCH INJECTION-PUMP ASSEMBLY 9400617449 1066762490 me153460

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 449 9400617449

ZEXEL 106676-2490 1066762490

MITSUBISHI ME153460 me153460

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Cross reference number

BOSCH 9 400 617 449 9400617449

ZEXEL 106676-2490 1066762490

MITSUBISHI ME153460 me153460

Zexel num

Bosch num

Firm num

Name

106676-2490

9 400 617 449

ME153460 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D24 K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131425-0220

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

Tester oil delivery pressure kPa 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.9 3.85 3.95

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 11.9

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 118.5 115.5 121.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8.5+-0.5

Pump speed r/min 410 410 410

Each cylinder's injection qty mm3/st. 15.8 13.4 18.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.9)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 118.5 117.5 119.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 117 113 121

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position (R1+0.7)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 124 120 128

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.65

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 112.5 106.5 118.5

Fixing the lever *

Timer adjustment

Pump speed r/min 800--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 2 1.5 2.5

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.
----------
T1=AE41
----------

Speed control lever angle

F:Full speed I:Idle (1)Viewed from feed pump side. (2)Stopper bolt set position 'H'
----------

----------
a=30deg+-5deg b=(36.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At pump speed aa and rack position bb, set the stopper bolt. (Confirm non-injection.) (2)Normal engine position (Rack position corresponding to cc)
----------
aa=1100r/min bb=3.5+-0.3mm cc=18mm
----------
a=40deg+-5deg b=25.5deg+-5deg c=(31deg)+-5deg

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=325r/min Ra=7.6+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=12deg
----------
a=(8deg)

Information:

If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
Dealer to perform most economical repair.
Description____________________________SMCS Code___Hours
Wash___________________________________1091-074 ___0.2
Inner fender __________________________7252-010 ___0.2
R&I DPF _______________________________108F-010 ___1.2
program ECM - program DPF serial # ,
ASH reset, factory passwords __________1901-591 ___0.2
Test after Repair _____________________108F-030 ___0.2
This letter is to be performed during a recommended ash service as stated in Media number SEBU8087. Ash cleaning is a part of the recommended maintenance of the engine, customer is responsible for the labor required to remove and install the DPF.
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Rework Procedure
1. Wash debris from Diesel Particulate Filter (DPF) as necessary.
Image1.1.1
2. Remove the Fender (A): Loosen and remove the nuts and bolts from the fender of the truck. Retain the fender and fasteners for reuse. Refer to Image 1.1.1.
Image1.2.1
3. Remove the Step (B): Loosen and remove fasteners from the step of the truck. Retain the step and fasteners for reuse. Refer to Image 1.2.1.
Image1.3.1
Image1.3.2
4. Remove the Pipe Clamps: Loosen and remove clamps from the Inlet Pipe (C)& Outlet Pipe (D) of the DPF?s. Refer to Image 1.3.1 & Image 1.3.2
Image1.4.1
5. Remove tubes (E) and sensor box mounting bolts (F) to unplug sensor box connection. Refer to Image 1.4.1.
Image1.5.1
6. Remove DPF mounting bolts: Loosen and remove fasteners from the mounting of the DPF. Retain the mounting and fasteners for reuse. No jack will be used to hold DPF, DPF is supported by air tank brackets. Properly support DPF until it rests on the bracket. Refer to Image 1.5.1.
Image1.6.1
7. Slide the DPF forward and remove. Remove the CGI pipe (G) after the DPF has been removed. Refer to Image 1.6.1.
Image 1.7.1 shows the chassis after the welded DPF has been removed.
Image1.7.1
Image1.7.2
8. Install the Clamped DPF with mounting bolts (reuse the bolts). Install the new 330-4036 CGI Pipe for Group 1 & Group 2 with the 304-3048 Clamp. Check Inlet, Outlet and CGI pipes alignment, mounting brackets should be aligned with OEM brackets.
Refer OEM guidelines for connecting Inlet & CGI connections.
Image 1.7.2 shows the clamped DPF after it has been installed in the chassis.
9. Install the step and fender that were removed in Step 2 and Step 3.
10. Reset the engine ash model. Refer Media Number RENR9705.
11. Start the engine and use CAT ET to ensure that the status parameter Diesel Particulate Trap #1 Differential Pressure has a value greater than zero. Also ensure status parameters Diesel Particulate Trap #1 Intake Temperature, and Diesel Particulate Trap #1 Outlet Temperature show reasonable values and increase with the rising exhaust temperatures.