101603-6860 ZEXEL 9 400 610 652 BOSCH INJECTION-PUMP ASSEMBLY 9400610652 1016036860 me035346


 

Information injection-pump assembly

BOSCH 9 400 610 652 9400610652
ZEXEL 101603-6860 1016036860
MITSUBISHI ME035346 me035346
101603-6860 INJECTION-PUMP ASSEMBLY
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Buy INJECTION-PUMP ASSEMBLY 101603-6860 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-6860 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-9700
3. GOVERNOR 105931-3830
4. SUPPLY PUMP 105210-4641
5. AUTOM. ADVANCE MECHANIS 105643-0090
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6030
11. Nozzle and Holder ME035655
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105031-3900
14. NOZZLE 105015-5700
15. NOZZLE SET

Include in #1:

101603-6860 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 610 652 9400610652
ZEXEL 101603-6860 1016036860
MITSUBISHI ME035346 me035346


Zexel num
Bosch num
Firm num
Name
101603-6860 
101606-6170 
9 400 610 652 
ME035346  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D14 * 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   131424-5520
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   3.3 3.25 3.35
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
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   65 63 67
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   H
Rack position   9.5+-0.5
Pump speed r/min   275 275 275
Each cylinder's injection qty mm3/st.   10.5 9 12
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   65 64 66
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(11)
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   77.5 75.5 79.5
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1(11)
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   51.5 49.5 53.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   14.1+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   90 70 110
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1250--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1350
Advance angle deg.   2.4 1.9 2.9
Timer adjustment_04
Pump speed r/min   1500
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101603-6860
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=A10
----------

Speed control lever angle

Test data 101603-6860
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=40.5deg+-3deg

Stop lever angle

Test data 101603-6860
N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at speed = rated point and rack position = aa (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt , confirm non-injection at pump speed bb. Rack position = cc (non-injection rack position). (3)Rack position = approximately dd (4)Free (at shipping)
----------
aa=5.4mm bb=275r/min cc=7.4mm dd=15mm
----------
a=41deg+-5deg b=(29.5deg) c=15.5deg+-3deg

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=400+-5r/min Ra=9.2mm
----------

Timing setting

Test data 101603-6860
(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=13deg
----------
a=(0deg)




Information:

No. 2D diesel fuel is recommended for use in the 1100 Series Caterpillar Diesel Truck Engines, although No. 1D may be used if desired.In selecting a fuel, note that distillate fuels are especially desirable because the fuel is heated to a vaporous state and condensed, thus eliminating all sediment and residue.There is considerable variation in the composition of fuels distributed under the No. 2D grade classifications. For desirable engine service it is most important to give special attention to cetane no., water and sediment, pour point, cloud point and sulphur content. USE FUELS WHICH MEET THE FOLLOWING REQUIREMENTS:Cetane No. ... 40 minimumWater and Sediment ... 0.1% maximumPour Point ... 10F° (-12C°) below ambient temperatureCloud Point ... No higher than ambient temperatureSulphur Content ... Above 0.4% adjust oil change periodGravity ... 32-40 A.P.I. at 60°F (16°C) Cetane No.: This is an indication of a fuel's ignition quality and should not be less than 40 for this engine. For high altitude operation or cold weather starting, a higher cetane number is required. Water and Sediment: A good clean fuel will contain no more than .1% sediment and water. Dirty fuels lead to early filter plugging and in addition can result in the formation or gums and resins reducing filter and engine life. Pour Point: The pour point of the fuel has no effect on engine performance, as long as the fuel is fluid enough to flow from the fuel tank to the engine. The pour point of the fuel should be at least 10F° (-12°C) below the lowest atmospheric temperature at which the engine must start and operate. In extremely cold temperatures it may be necessary to use No. 1D diesel fuel. Cloud Point: Cloud point is the temperature at which wax crystals become visible and is generally above the pour point of the fuel. The cloud point should be no higher than the lowest atmospheric temperature at which the engine must start to keep the fuel filter elements from plugging with wax crystals. Sulphur Content: As sulphur content increases, the crankcase oil change periods should be reduced. Fuel containing 0.4% or less sulphur content, use normal oil change periods. If the fuel contains 0.4% to 1.0% sulphur, oil change periods should be reduced to one-half normal interval. If the fuel contains more than 1.0% sulphur, oil change periods should be reduced to one-fourth normal interval. Gravity: Gravity is the measurement of heat units in a certain amount of fuel. The heavier the fuel (the lower the number) the more heat units per volume. If a fuel with a higher A.P.I. gravity is used the power produced will be lower. Select fuels with the lower A.P.I. gravity reading.Authorized dealers are familiar with fuels that have given good results in Caterpillar Diesel Engines and should be consulted regarding the fuel to use.

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