101606-1320 ZEXEL 9 400 615 438 BOSCH INJECTION-PUMP ASSEMBLY 9400615438 1016061320 me056641


 

Information injection-pump assembly

BOSCH 9 400 615 438 9400615438
ZEXEL 101606-1320 1016061320
MITSUBISHI ME056641 me056641
101606-1320 INJECTION-PUMP ASSEMBLY
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Service parts 101606-1320 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4260
3. GOVERNOR 105490-5340
4. SUPPLY PUMP 105210-4151
5. AUTOM. ADVANCE MECHANIS 105614-4100
6. COUPLING PLATE 105662-0590
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-6021
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105030-5010
14. NOZZLE 105015-5390
15. NOZZLE SET

Include in #1:

101606-1320 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 438 9400615438
ZEXEL 101606-1320 1016061320
MITSUBISHI ME056641 me056641


Zexel num
Bosch num
Firm num
Name
101606-1320 
101606-6240 
9 400 615 438 
ME056641  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D22 K 14BF INJECTION PUMP ASSY PE6AD PE

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   131424-5120
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   4.5 4.45 4.55
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   9.6
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   112 108.6 115.4
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   8+-0.5
Pump speed r/min   225 225 225
Each cylinder's injection qty mm3/st.   18.5 15.7 21.3
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(9.6)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   112 111 113
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(9.6)
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   113.5 111 116
Difference in delivery mm3/st.   9 9 9
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   E
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   140 120 160
Fixing the lever   *
Remarks
After startup boost setting
 
Timer adjustment
Pump speed r/min   850--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   800
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1000
Advance angle deg.   0.9 0.4 1.4
Timer adjustment_04
Pump speed r/min   1150
Advance angle deg.   3 2.5 3.5
Timer adjustment_05
Pump speed r/min   -
Advance angle deg.   4 4 5
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 101606-1320
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Excess fuel setting for starting: SXL (4)Damper spring setting: DL
----------
RT=1 TH=2.9mm SXL=R1+0.2mm DL=6.8-0.2mm
----------

Speed control lever angle

Test data 101606-1320
F:Full speed
----------

----------
a=10deg+-5deg

0000000901

Test data 101606-1320
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=21deg+-5deg b=29deg+-3deg

Stop lever angle

Test data 101606-1320
N:Pump normal S:Stop the pump. (1)Free (at shipping) (2)Rack position = aa (3)Rack position = bb, set the stopper bolt.
----------
aa=13.5mm bb=6-0.5mm
----------
a=(58deg) b=36deg+5deg-7deg c=24deg+-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
----------
N1=325+-5r/min Ra=7.3mm
----------

Timing setting

Test data 101606-1320
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(7deg)




Information:

Literature Information
This manual contains safety, operation instructions, lubrication and maintenance information. This manual should be stored in or near the engine area in a literature holder or literature storage area. Read, study and keep it with the literature and engine information.Some photographs or illustrations in this manual show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes. Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this manual. Whenever a question arises regarding your engine, or this manual, please consult your Caterpillar dealer for the latest available information. Safety
The safety section lists basic safety precautions. In addition, this section identifies hazardous, warning situations. Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.Operation
Operating techniques outlined in this manual are basic. Skill and techniques develop as the operator gains knowledge of the engine and its capabilities, and to assist with developing the skills and techniques required to operate the engine more efficiently and economically.The operation section is a reference for operators, and photographs and illustrations guide the operator through procedures of inspecting, starting, operating and stopping the engine. This section also includes a discussion of GSC display window indicators, features and controls, and electronic diagnostic information.Maintenance
The maintenance section is a guide to engine care. The illustrated, step-by-step instructions are grouped by fuel consumption, service hours and/or calendar time maintenance intervals. Items in the Maintenance Schedule are referenced to detailed instructions that follow.Use fuel consumption or service hours to determine intervals. Calendar intervals shown (daily, annually, etc.) may be used instead of service meter intervals if they provide more convenient schedules and approximate the indicated service meter reading.Recommended service should always be performed at the service hour interval. The actual operating environment of the engine also governs the maintenance schedule. Therefore, under extremely severe, dusty, wet or freezing cold operating conditions, more frequent lubrication and maintenance than is specified in the Maintenance Schedule may be necessary.The Maintenance Schedule items are organized for a Preventive Maintenance Management Program. If the Preventive Maintenance Program is followed, a periodic tune-up is not required. The implementation of a Preventive Maintenance Management Program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.Maintenance Intervals
Perform maintenance on items at multiples of the original requirement. Each level and/or individual items in each level should be shifted ahead or back depending upon your specific maintenance practices, operation and application. We recommend that the maintenance schedules be reproduced and displayed near the engine as a convenient reminder. We also recommend that a maintenance record be maintained as part of the engine's permanent record. See the Maintenance Records section in this manual for information regarding documents that are generally accepted as proof of maintenance or repair. Your authorized Caterpillar engine dealer can assist you in tailoring your Maintenance Schedule

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