101602-8230 ZEXEL 9 400 610 616 BOSCH INJECTION-PUMP ASSEMBLY 9400610616 1016028230 1156031030

Governor Actuator Mounting Replacement:
Removal Of The Previous Assembly
1. Disconnect linkage from cylinder and fuel pump, disassemble bracket from fuel pump lever.2. Remove cylinder from mounting plate, twist out rod end from cylinder.3. Remove mounting plate.Installing Of The New Linkage
1. Install 1433909, 8T4908, 8T4224, 9X6032, 8T4121 Linkage Assembly to engine block.2. Screw in U-joint of 1233885 Cylinder Rod as close as possible, tighten with 1426000 Nut, assemble cylinder with 8T1160 Bolts to the hinge.3. Assemble lever with washer and lock nut (1392085, 8T0389, 1392082, 8T4121), check free movement.4. Disconnect electrical connector from cylinder, turn on ignition, so that cylinder extends.5. Ensure pre-adjustment (overlapping of 1 mm) of U-joint and lever using the 8T4195 Stop Screw; tighten screw with nut (8T4133); See Illustration 2.6. Connect electrical connector to the cylinder and link up rod and lever with the 1233884 Pin.
Illustration 2Calibration
All adjustments have to be done with machine / engine at operating temperature
1. Start the engine.2. Plug-in PDT (portable diagnostic tool), choose menu "PROC" number 5 "ENGINE RPM" and number 6 "RPM DIFFERENCE". High And Low Idle Adjustment At Injection Pump:
1. Actuate the lever of the fuel injection pump by hand and adjust high and low idle by turning the corresponding stop screw at the fuel injection pump. If necessary fix the lever in the high idle position by use of a light spring to make adjustment easier:Set low idle to: 750 Rpm -20/+0 RpmSet high idle to : 2400 Rpm -0/+20 Rpm2. Make sure that when this is set a 1 mm spacer is fitted between the throttle lever and the high idle adjustment screw (see Illustration 3).3. Secure stop screw with locking nut. Seal setting with lockwire and lead seal, use your CAT dealer identification pliers.4. Disconnect electrical connector from the actuator (actuator piston extends completely).5. Stop the engine.6. Assemble and connect the 1413978 or 1397394, 9X8256, 1400277, 6V7743, 5C2890, 1107299, 1396903 Adjustable Rod, use the center hole at the fuel injection pump lever. Make sure that there is no contact between the fuel injection pump lever and the stop screw at high idle position.7. Start the engine.8. Adjust high idle setting with the rod:M312: high idle 2150 Rpm -0/+20 Rpm.M315: high idle 2400 Rpm -0/+20 Rpm.9. Secure the rod with the nuts at the ball joints.10. Mark the lock nut positions at the ball joints with a paint dot or using a felt-tip pen.11. Connect the electrical connector to the actuator.
Illustration 3Calibration/Adjustment Of The Engine
1. Press "F 1" key at the PDT for calibration.2. Choose item number 2 "CALIBRATION".3. Choose item number 1 "SPEED DIAL CAL".4. "MIN POSITION" setting, turn potentiometer on the panel until you receive the minimum voltage shown in the screen, press "ENTER".5. "MAX POSITION" setting, turn potentiometer until you receive maximum voltage shown in the screen, press "ENTER".6. You automatically get back into the previous menu, now choose number 2 "SPEED CAL".7. Change the low idle setting to 1020 Rpm by using the "UP- "or "DOWN-ARROW" keys at the PDT, when finished,