101607-6440 ZEXEL 9 400 615 701 BOSCH INJECTION-PUMP ASSEMBLY 9400615701 1016076440 me077804


 

Information injection-pump assembly

BOSCH 9 400 615 701 9400615701
ZEXEL 101607-6440 1016076440
MITSUBISHI ME077804 me077804
101607-6440 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 400 615 701 9400615701
ZEXEL 101607-6440 1016076440
MITSUBISHI ME077804 me077804


Zexel num
Bosch num
Firm num
Name
101607-6440 
9 400 615 701 
ME077804  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D16 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   11.7
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   77.4 75.1 79.7
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(11.7)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   77.4 76.4 78.4
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.55
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   87.7 83.7 91.7
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.4
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   56 52 60
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   E
Rack position   (R1+0.5)
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   87.6 83.6 91.6
Fixing the lever   *
Injection quantity adjustment_07
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 101607-6440
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=H50
----------

Speed control lever angle

Test data 101607-6440
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=(42deg)+-3deg

Stop lever angle

Test data 101607-6440
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

Test data 101607-6440
(A) Accelerator lever stopper bolt (B) Link (c) Nut (D) Lever (E) Pin (f) lever (G) Stopper bolt (H) Return spring (J) Pin (E) contacts lever. (K) Load sensor terminal (1)Black (2)Blue-yellow (3)Blue-red Setting the accelerator lever angle, load sensor adjustment 1. Accelerator lever setting method (1)Position the speed lever against the idle stopper bolt and fix. (2)Screw in the accelerator lever stopper bolt (A) and back off the stopper bolt (A) from the position where the accelerator lever pin contacts the speed lever and set. (Gap: approx. 1 mm) Tightening torque: 4.9~7 N.m {0.5~0.7 kgf.m} 2. Load sensor adjustment (See fig 1) (1)Load sensor output measuring circuit Apply DC5+-0.01V to the load sensor terminals and measure the output voltage. (2)Load sensor output adjustment procedure Hold the speed lever against the full side stopper bolt and fix. Adjust the load sensor output voltage to VF = 0.417+-0.1 V using the link (B) and then fix temporarily using nut (C). Turn the speed lever from the idle side to the full side and confirm that output voltage VF = 0.417+-0.1 V is obtained. Confirm several times and then fix using nut (C). Tightening torque: 3.4~4.9 N.m {0.35~0.5 kgf.m} 3. Setting the step motor's idle side stopper bolt After adjustment in previous 1 and 2, position speed lever against idle stopper bolt and fix. Then, screw in stopper bolt G until step motor lever D's pin E contacts lever F. Back off 10+2 deg (approx. 3.5 mm) from this position and fix G. (See fig. 3) 4. Speed lever return confirmation (1)Remove return spring (H) and confirm that the speed lever is returned to the idle position by the torsion spring. (2)Reinstall the return spring (H) in its original position.
----------

----------

Timing setting

Test data 101607-6440
(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:


Recommended engine warm-up procedure must be followed. Refer to the engine Operation and Maintenance Manual. Also refer to the relevant “Lubricant Viscosities for Ambient Temperatures” table footnote in this Special Publication.
Excessive engine idling time can contribute to excessive water in the crankcase oil, causing corrosion, sludge, and other problems. Excessive engine idling time can also lead to injector fouling, piston and combustion chamber deposits, corrosive damage, and increased oil consumption.
For proper selection of oil viscosity grade and oil type and/or specification, refer to this Special Publication, "Lubricant Specifications" section.Also, refer to this Special Publication, "Lubricant Viscosities" article.
Not following the recommendations found in the “Lubricant Viscosities for Ambient Temperatures” table and associated footnotes can lead to reduced performance and engine failure.
Do NOT use only the oil viscosities when determining the recommended oil for an engine compartment. The oil type (performance requirements) MUST also be used.
For easier cold weather starting, make sure that all of the components of the engine electrical system are properly maintained. All electrical wiring and connections should be free of the following: fraying, damaged insulation and corrosion. Batteries should be kept fully charged and warm. The batteries and the battery cables must be sized properly for the application.Various starting aids are available in order to assist with cold engine starts in low temperature conditions. Follow the recommendations that are provided by the manufacturer of the starting aid. Refer to the foreword section of this Special Publication, "Aftermarket Products and Warranty".For additional information concerning cold-weather operation, refer to this Special Publication, "Fuel Specifications" section. Also refer to this Special Publication, "Cooling System Specifications" section.Before attempting to start the engine, make sure that the oil in the engine is fluid enough to flow. Check the oil by removing the dipstick. If the oil will drip from the dipstick, then the oil should be fluid enough to allow the engine to start. Do not use oil that has been diluted with kerosene. Kerosene will evaporate in the engine. and cause the oil to thicken. Kerosene will cause swelling and softening of the silicone seals. Kerosene will dilute the oil additives. Dilution of the oil additives will reduce the performance, and reduce the engine protection that the additives provide.If the viscosity of the oil is changed for colder weather, also change the filter element. If the filter is not changed, the filter element and the filter housing can become a solid mass. After you change the oil, operate the engine in order to circulate the thinner oil.When you start a cold-soaked engine or when you operate an engine in ambient temperatures that are below −18°C (0°F), use base oils that can flow in low temperatures. These multigrade oils have lubricant viscosity grade of

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