101606-1210 ZEXEL 9 400 615 430 BOSCH INJECTION-PUMP ASSEMBLY 9400615430 1016061210 me047475

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 430 9400615430

ZEXEL 101606-1210 1016061210

MITSUBISHI ME047475 me047475

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Buy INJECTION-PUMP ASSEMBLY 101606-1210 zexel genuine, new aftermarket engine parts with delivery

Service parts 101606-1210 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-8980

3. GOVERNOR 105490-5320

4. SUPPLY PUMP 105210-4840

5. AUTOM. ADVANCE MECHANIS 105643-0120

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6500

11. Nozzle and Holder ME047128

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

13. NOZZLE-HOLDER 105031-3900

14. NOZZLE 105015-6230

15. NOZZLE SET

Include in #1:

101402-4440 as _

101606-1210 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 615 430 9400615430

ZEXEL 101606-1210 1016061210

MITSUBISHI ME047475 me047475

Zexel num

Bosch num

Firm num

Name

101606-1210

9 400 615 430

ME047475 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D16T * 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 4.2 4.15 4.25

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 A

Rack position 11.5

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 101.6 100.6 102.6

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.3+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 12 10.5 13.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 8+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 14.1 12.6 15.6

Fixing the rack *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Adjust with the load control lever in the full position (variable speed specification). (3)Lever ratio: RT (4)Target shim dimension: TH (5)Excess fuel setting for starting: SXL (6)Damper spring setting (7)Main spring setting (8)Set idle sub-spring (9)When air cylinder is operating.
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RT=1 TH=2.2mm SXL=12.5+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Pump speed = bb (3)Pump speed cc (4)Use the hole above R = dd
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aa=1400r/min bb=1150r/min cc=350r/min dd=190mm
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a=6deg+-5deg b=21deg+-5deg c=3deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
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aa=70mm
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a=22deg+-3deg b=31.5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa
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aa=5mm
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a=57deg+-5deg b=55.5deg+-5deg

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
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N1=400r/min Ra=8mm
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0000001601 2-STAGE CHANGEOVER DEVICE

RFD governor 2 stage changeover mechanism adjustment outline (A) Bolt (B) bolt (c) Nut (D) Return spring (E) Bolt (F) Bolt (G) Screw (H) Bolt (I) Load lever (J) Speed lever (K) Air cylinder (M Air inlet Figure 1 is only for reference. Lever shape, etc, may vary. 1. Minimum-maximum speed specification adjustment (when running) (a) Without applying air to the air cylinder, loosen bolts (A) and (B). (1)High speed return L setting (a) In the speed range Nf~Nf - 300r/min, adjust using the speed adjusting bolt to determine the temporary beginning of high speed control speed. (b) Determine the rack position in the vicinity of Rf using the full load lever. (c) Increase speed and confirm return distance L. (d) Adjust using the tension lever bolt to obtain L. (2)Setting full load rack position Rf (a) Move the load control lever to the full side. (b) Adjust the full load adjusting bolt so that Rf can be obtained, then fix. (3)Setting the beginning of high speed operation Nf (a) Adjust using bolt (E) so that Nf can be obtained, and then fix. (4)Idle control setting (Re, Ni, Rc) (a) Set the speed at Ns + 200r/min and move the load control lever to the idle side. (b) Fix the lever in the position where Re can be obtained. (c) Next, decrease speed to Ni and screw in the idle spring. (d) Adjust to obtain rack position Ri. (e) Increase the speed and after confirming that the rack position is Re at Ns, set the speed at 0. (f) Confirm protrusion position Rc at idle. (5)Damper spring adjustment (a) Increase speed and set the speed at the rack position Rd - 0.1 mm (b) Set using the damper spring so that the rack position Rd can be obtained. (c) When Rd is not specified, Rd = Ri - 0.5 mm. (6)High speed droop confirmation (a) Return the load control lever to the full load lever position. (b) Increase the speed and confirm that Rf can be obtained at Nf r/min. (c) Confirm that speed is Nh at rack position Rh. 2. Variable speed specification adjustment (at operation) (a) Remove return spring (D). (b) Apply air pressure of 245~294 kPa {2.5~3 kg/cm2} to the air cylinder. (c) Perform the following adjustment in this condition. (1)Setting full load rack position Rf' (a) Pull the load lever to the idle side. (b) Obtain rack position Rf' using the nut (C). (Pump speed is Nf'-50 r/min.) (2)Setting full speed Nf' (a) Adjust using bolt (B) so that Nf can be obtained, and then fix. (3)Low speed side setting (a) At 350r/min, set bolt (F) at beginning of governor operation position, then fix. 3. Bolt (A) adjustment (1)Install return spring (D) and perform the adjustments below at air pressure 0. (a) Set at speed Nf using bolt (E). (b) Screw in bolt (A). (c) Screw in 1 more turn from the speed lever contact position (d) Fix bolt (A). (e) At this time confirm that the air cylinder's shaft moves approximately 1 mm towards the governor. 4. Lever operation confirmation using the air cylinder (1)Apply 588 kPa {6 kg/cm2} air pressure to the air cylinder. (2)Confirm that the cylinder piston is moved 50 mm by the spring (D).
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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)-
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aa=14deg
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a=(1deg)

Information:

Scheduled Oil Sampling (S O S) oil analysis is the best indicator for determining what is happening inside your engine.S O S oil analysis is a diagnostic tool used to determine oil performance and component wear rates. S O S oil analysis uses a series of tests designed to identify and measure contamination such as: * soot, sulfur, etc.* degradation such as the presence of fuel, water and antifreeze in a sample of oil.* the amount of wear metals present in the oil sample.Wear metals present in the oil sample are compared to established Caterpillar norms to determine acceptability. S O S oil analysis must be performed on a continuing basis to be effective as an indicator. Intermittent sampling does not allow wear rate trend lines to be established. Obtain S O S samples at regularly scheduled intervals to monitor the condition and maintenance requirements of your engine. Each oil sample should be taken when the oil is warm and well mixed to ensure that the sample is representative of the oil in the engine crankcase.Consult with your Caterpillar dealer for complete information and assistance in establishing an S O S oil analysis program for your engine(s).S O S Oil Analysis
S O S oil analysis is composed of three basic tests: * Wear Analysis* Chemical and Physical Tests* Oil Condition Analysis Wear analysis is performed with an atomic absorption spectrophotometer to monitor component wear by identifying and measuring concentrations, in parts per million, of wear elements present in the oil. Based on known normal concentration data, maximum limits of wear elements are established. Impending failures can be identified when test results deviate from concentration levels established as acceptable, based on normal wear. Chemical and physical tests detect the presence of water, fuel and glycol (antifreeze) in the oil and determine whether or not their concentrations exceed established maximum limits. Oil condition is evaluated with infrared analysis. This test determines the presence and measures the amount of contaminants such as soot, sulfur products, oxidation, and nitration products in the oil. Infrared analysis can also assist in customizing (reducing, maintaining or extending) oil change intervals for particular conditions and applications.Infrared analysis should always be accompanied by wear element analysis and chemical and physical tests to assure accurate diagnosis. Infrared analysis must be used to determine oil change intervals. Oil analysis must include Infrared (IR) in the analysis.The test results of the oil samples will then be used as a basis for determining the oil change interval for your engine, giving you the ultimate time between oil changes without the risk of engine damage.Refer to PEDP1129, Listen To Your Oil, for information and benefits of S O S oil analysis.