101608-1090 ZEXEL 9 400 615 774 BOSCH INJECTION-PUMP ASSEMBLY 9400615774 1016081090 me075717

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 774 9400615774

ZEXEL 101608-1090 1016081090

MITSUBISHI ME075717 me075717

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Service parts 101608-1090 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8391

3. GOVERNOR 105931-9380

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105643-1090

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7062

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE

15. NOZZLE SET 105019-0230

Include in #1:

101608-1090 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-5560 as _

Cross reference number

BOSCH 9 400 615 774 9400615774

ZEXEL 101608-1090 1016081090

MITSUBISHI ME075717 me075717

Zexel num

Bosch num

Firm num

Name

101608-1090

9 400 615 774

ME075717 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

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)Use the hole at R = aa (2)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 (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=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

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:

Ensure that all components are free of contaminants before installing. Contaminants may cause premature wear and reduced component service life.
Note: Disposition and Recycling - Common components of exhaust aftertreatment devices include, but are not limited to, cordierite, silicon carbide, iron zeolite, vanadium, platinum, and palladium. After the devices are used in an engine exhaust flow they can include some by-products that result from combustion. Follow applicable Federal, State, and local regulations when handling or discarding used aftertreatment devices
Illustration 1 g03842051
Note: Prior to removal of the catalyst, identify the position of the catalysts and airflow direction. Ensure that the catalyst part number position and the air flow direction remain the same.
Remove Diesel Particulate Filter (DPF) hatch cover (1) nuts, bolts, and washers.
Remove hatch cover (1) from the reactor unit.
Remove gasket assembly from the sealing surface of the hatch cover.
Carefully remove DPF catalyst assembly by removing the V band clamps. If necessary, repeat for other PDF catalysts. Take note of DPF air flow direction and location for reassembly.
Carefully install DPF catalyst into the cabinet with new gaskets. Verify correct position and air flow direction of the DPF.
DPF should always be installed in the direction shown in illustration 1. The long end of the DPF should be installed in the sleeve of the reactor and secured with the proper V band clamps.
For verified applications, replacement DPFs must have the proper tags and meet all documentation requirements.
Apply final torque to V band clamps. Refer to Specifications, SENR3130, "Torque Specifications" for the proper torque.
Replace all inner backing strip gaskets on the DPF catalyst cover.
Install DPF cover assembly.
Replace all damaged bolts.
Apply final torque to all bolts in a circular pattern. Refer to Specifications, SENR3130, "Torque Specifications" for the proper torque.
Verify that all bolts are at the proper torque value.