101608-1110 ZEXEL 9 400 615 776 BOSCH INJECTION-PUMP ASSEMBLY 9400615776 1016081110 me075719

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 776 9400615776

ZEXEL 101608-1110 1016081110

MITSUBISHI ME075719 me075719

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Service parts 101608-1110 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8391

3. GOVERNOR 105932-0050

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:

101608-1110 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-5580 as _

Cross reference number

BOSCH 9 400 615 776 9400615776

ZEXEL 101608-1110 1016081110

MITSUBISHI ME075719 me075719

Zexel num

Bosch num

Firm num

Name

101608-1110

9 400 615 776

ME075719 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=G43
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=18.5deg+-5deg b=(42deg)+-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=(42deg)+-3deg c=18.5deg+-5deg

0000001601 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 2. Idle side microswitch adjustment (OPEN type) Confirm with the lever angle at idle. (1)Speed N2 (2)Rack position Rb
----------
N1=1675r/min Ra=8.5+-0.1mm N2=275r/min Rb=9.7+-0.1mm
----------

0000001701 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
----------

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:

Illustration 6 g06375966
Current hose routing
(E) 3U-2752 Clip
Illustration 7 g06375968
(D3) 32.31 mm (1.272 inch)
(D4) 80.00 mm (3.150 inch)
(1) 178-7023 Boss
Illustration 8 g06375967
New hose routing
(1) 178-7023 Boss
(2) 420-5299 Clip
Remove clip (E) and install boss (1) per the dimensions and secure the hose using two double clips (2), as shown in Illustration 6, Illustration 7, and Illustration 8.Changes to CEM Line Routing for 730C2, 730C2 EJ, 730, and 735 Articulated Trucks
Illustration 9 g06376002
Current hose routing
(F) 421-9627 Bracket As
(G) 3U-2752 Clip
(H) 7K-1181 Cable Strap
Remove bracket assembly (F), clips (G), strap cable (H), and other mounting hardware, as shown in Illustration 9.
Illustration 10 g06376255
New hose routing
(2) 420-5299 Clip
Install two double clips (2) as shown in Illustration 10.Note: The hose routing simplifies the installation and provides additional clearance to the oil gallery on the right-hand side of the machine.Changes to DEF cooling Lines Routing (To/From Tank) for all High Regulated Countries (HRC) Machines
Illustration 11 g06376256
Current hose routing
(J) 312-0288 Clamp
Illustration 12 g06376257
New hose routing
(3) 520-7003 ClampRemove old clamps (J) and replace with the new clamps (3), as shown in Illustration 11 and Illustration 12.Changes to DEF Cooling Lines Routing (To Pump- Both ends) for all HRC Machines
Illustration 13 g06376263
Current clamp
(J) 312-0288 Clamp
Illustration 14 g06376264
New clamp
(3) 520-7003 Clamp
Illustration 15 g06376266
Current clamp
(J) 312-0288 Clamp
Illustration 16 g06376267
New clamp
(3) 520-7003 ClampRemove old clamps (J) and replace with the new clamps (3), as shown in Illustration 13, Illustration 14, Illustration 15, and Illustration 16.Changes to DEF Cooling Lines (From Pump- Both ends) Routing for all HRC Machines
Illustration 17 g06376285
Current clamp
(K) 433-0933 Clamp
Illustration 18 g06376288
New clamp
(4) 520-7002 ClampRemove existing clamps (K) and replace with the new clamps (4), as shown in Illustration 17 and Illustration 18.