101606-1330 ZEXEL 9 400 615 439 BOSCH INJECTION-PUMP ASSEMBLY 9400615439 1016061330 me056642


 

Information injection-pump assembly

BOSCH 9 400 615 439 9400615439
ZEXEL 101606-1330 1016061330
MITSUBISHI ME056642 me056642
101606-1330 INJECTION-PUMP ASSEMBLY
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Service parts 101606-1330 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-4260
3. GOVERNOR 105490-5350
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 ME056371
12. Open Pre:MPa(Kqf/cm2) 21.6(220)
13. NOZZLE-HOLDER 105030-5010
14. NOZZLE 105015-5390
15. NOZZLE SET

Include in #1:

101606-1330 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 439 9400615439
ZEXEL 101606-1330 1016061330
MITSUBISHI ME056642 me056642


Zexel num
Bosch num
Firm num
Name
101606-1330 
101606-6390 
9 400 615 439 
ME056642  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D22 * 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   131424-5120
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   9.9
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   120 116.6 123.4
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(9.9)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   120 119 121
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(9.9)
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   123.7 121.2 126.2
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.   140 100 180
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 101606-1330
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=6-0.2mm
----------

Speed control lever angle

Test data 101606-1330
F:Full speed
----------

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

0000000901

Test data 101606-1330
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=21deg+-5deg b=30deg+-3deg

Stop lever angle

Test data 101606-1330
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=6.1-0.5mm
----------
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
----------

0000001601 ACS

Test data 101606-1330
Aneroid compensator adjustment (1)Adjust the clearance between the aneroid compensator's main body and the push rod to L1. (2)Pump speed N1 at load lever's full position. (3)Screw in the aneroid compensator body to obtain the performance shown in the graph above.
----------
L1=0.1~0.5mm N1=700r/min
----------
Ra=9.9mm Rb=(9.2)mm P1=(88.6)kPa((665)mmHg) P2=69+-0.7kPa(518+-5mmHg) Q1=120+-1cm3/1000st Q2=100.5+-1cm3/1000st

Timing setting

Test data 101606-1330
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

Oils
Hot oil and components can cause personal injury. Do not allow hot oil or components to contact the skin.Keep all exhaust manifold and turbocharger shields in place to protect hot exhaust from oil spray in the event of a line, tube or seal failure.Batteries
Always wear protective glasses when working with batteries. Battery electrolyte contains acid and can cause injury. Avoid contact with the skin and eyes.Wash hands after touching batteries and connectors. Use of gloves is recommended.Do not smoke when observing the battery electrolyte levels. Batteries give off flammable fumes which can explode. Ensure there is proper ventilation for batteries which are located in an enclosure.Never disconnect any charging unit circuit or battery circuit cable from the battery when charging unit is operating. A spark can cause the flammable vapor mixture of hydrogen and oxygen to explode.Fire or Explosion Prevention
Fire may result from lubricating oil or fuel sprayed on hot surfaces causing personal injury and property damage. Inspect all lines and tubes for wear or deterioration. They must be routed, supported or clamped securely. Tighten all connections to the recommended torque. Leaks can cause fires. Determine whether the engine will be operated in an environment in which combustible gases could be drawn through the air inlet system. These gases could cause the engine to overspeed, which in turn could seriously damage the engine and result in bodily injury or property damage.If your application involves the presence of combustible gases, consult your Caterpillar dealer to obtain additional information concerning protection devices suitable for the application involved.All fuels, most lubricants and some coolant mixtures are flammable. Diesel fuel is flammable. Gasoline is flammable. The mixture of diesel and gasoline fumes are extremely explosive.Do not smoke while refueling or in a refueling area.Do not smoke in areas where batteries are charged, or where flammable materials are stored.Always thaw a frozen battery before jump starting. Frozen batteries may explode. Batteries give off flammable fumes which can explode.Keep all fuels and lubricants stored in properly marked containers and away from all unauthorized persons.Store all oily rags or other flammable material in a protective container, in a safe place.Do not weld or flame cut on pipes or tubes that contain flammable fluids. Clean them thoroughly with nonflammable solvent before welding or flame cutting on them.Remove all flammable materials such as fuel, oil and other debris before they accumulate on the engine.Exhaust shields (if equipped), which protect hot exhaust components from oil or fuel spray in the event of a line, tube or seal failure, must be installed correctly.Provide adequate and proper waste oil disposal. Oil and fuel filters must be properly installed and housing covers tightened to proper torque when being changed.Batteries must be kept clean, covers kept on all cells, recommended cables and connections used and battery box covers kept in place when operating. When starting from an external source, always connect the positive (+) jumper cable to the POSITIVE (+) terminal of the battery of the engine to be

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