101605-9531 ZEXEL 9 400 611 514 BOSCH INJECTION-PUMP ASSEMBLY 9400611514 1016059531 3436103070

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 514 9400611514

ZEXEL 101605-9531 1016059531

MITSUBISHI-HEAV 3436103070 3436103070

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Service parts 101605-9531 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8120

3. GOVERNOR 105412-2421

4. SUPPLY PUMP 105220-6430

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5210

11. Nozzle and Holder 34361-11010

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

13. NOZZLE-HOLDER 105048-3330

14. NOZZLE

105017-1180

15. NOZZLE SET

Include in #1:

101401-4952 as _

101605-9531 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 514 9400611514

ZEXEL 101605-9531 1016059531

MITSUBISHI-HEAV 3436103070 3436103070

Zexel num

Bosch num

Firm num

Name

101605-9531
101609-9120

9 400 611 514

3436103070 MITSUBISHI-HEAV

INJECTION-PUMP ASSEMBLY
S6K 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 131424-5720

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 3.6 3.55 3.65

Beginning of injection position
Drive 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 A

Rack position 6.9

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 39.2 38.2 40.2

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6.6+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 12 10.7 13.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 60 60 65

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)The torque control spring must does not have a set force. (5)Set idle sub-spring (6)Main spring setting (7)Rack difference between N = N1 and N = N2
----------
K=15 N1=1100r/min N2=750r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(21deg)+-5deg b=(27deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Hold the boss against the stop side (2)Use the hole at R = aa
----------
aa=60mm
----------
a=53deg+-5deg b=26.5deg+-5deg c=(9deg)

Timing setting

(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

Caterpillar Reference Material
Lubricants
Oil and Your Engine SEBD0640Scheduled Oil Sampling PEDP1129Branded Fluids Question & Answer Booklet PEDP7122Cat Fluids - Molybdenum Grease (MPGM) PEHP0002Cat Fluids - Lithium Grease (MPGL) PEHP0003Cat Fluids - Special Purpose Grease (SPG) PEHP0017How to Take a Good Oil Sample PEHP6001Caterpillar Fluids Selector Dial PEWP9733Fuels
Diesel Fuels and Your Engine SEBD0717Coolants
Know Your Cooling System SEBD0518Coolant and Your Engine SEBD0970Service Manuals
3408 & 3412 Service Manual (9XM & 9XF) SENR4655Engine Supervisory System Operation Manual SEBU6260Special Instructions
The following Special Instructions pertain to the operation, maintenance, diagnostic tooling and programming of the Electronic system. Some of these publications will be included in the tool kits, the others will be available thru your Caterpillar dealer.Storage Procedure for Caterpillar Products SEHS9031Miscellaneous
Index to Guidelines for Reusable Parts and Salvage Operations SEBF8029Guideline for Reusable Parts (Cleaning and Inspection of Air Filters) SEBF8062Tag - DO NOT OPERATE SEHS7332All of the above publications are available through your Caterpillar dealer.Additional Reference Material
ASTM Specs can normally be obtained from your local technological society, library or college or contacting:* American Society for Testing and Materials
1916 Race St.
Philadelphia, PA 19103
(215) 299-5400
Society of Automotive Engineers (SAE) Specs can be found in your SAE handbook or can be obtained from your local library, college or technological society, or contacting:* Society of Automotive Engineers, Inc.
SAE International
400 Commonwealth Drive
Warrendale, PA USA 15096-0001
(412) 776-4841
American Petroleum Institute (API) classification system and oil selection for API Publication No. 1509 can be obtained from your local library, college or technological society, or contact:* American Petroleum Institute
1220 L St.
Washington, DC 20005
(202) 682-8000
Engine Manufacturers Association (EMA) information for lube oil selection can be obtained from your local library, college or technological society, or contact:* Engine Manufacturers Association
Lubricating Oils Data Book
401 N. Michigan Ave. Ste. 2400
Chicago, IL 60611
(312) 644-6610 ext. 3626