Information injection-pump assembly
BOSCH
F 01G 09U 04E
f01g09u04e
ZEXEL
101606-1521
1016061521
MITSUBISHI
ME076014
me076014
Rating:
Service parts 101606-1521 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME035748
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
F 01G 09U 04E
f01g09u04e
ZEXEL
101606-1521
1016061521
MITSUBISHI
ME076014
me076014
Zexel num
Bosch num
Firm num
Name
101606-1521
F 01G 09U 04E
ME076014 MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D15 * K
6D15 * K
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.5
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
69
66.9
71.1
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.9+-0.5
Pump speed
r/min
275
275
275
Each cylinder's injection qty
mm3/st.
9.2
8.1
10.3
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.5)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
69
68
70
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.35
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
82.5
78.5
86.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.2
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
47.6
43.6
51.6
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
80
75
85
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
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
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=C92
----------
----------
T1=C92
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=33deg+-5deg b=(42deg)+-3deg
----------
----------
a=33deg+-5deg b=(42deg)+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Free (at shipping)
(2)Rack position = approximately aa.
(3)Set the stopper bolt at speed = rated point and rack position = bb (non-injection rack position). Confirm non-injection.
(4)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
----------
aa=17.4mm bb=(7)mm cc=275r/min dd=(8)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-5deg
----------
aa=17.4mm bb=(7)mm cc=275r/min dd=(8)mm
----------
a=17deg+-5deg b=(27deg) c=2deg+-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=400+-5r/min Ra=9.7mm
----------
----------
N1=400+-5r/min Ra=9.7mm
----------
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)-
----------
aa=12deg
----------
a=(1deg)
----------
aa=12deg
----------
a=(1deg)
Information:
You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.For most users, a top end overhaul is not needed until the major OVERHAUL interval. A top end overhaul is generally indicated by increased fuel consumption and reduced power. This option consists of completely reconditioning your cylinder head, but the cylinder components are not worn enough to need repair. Overhaul Programs
Your Caterpillar dealer may be offering a variety of options regarding overhaul programs and Caterpillar recommends that an Overhaul be performed at this maintenance interval.Overhaul Options
Caterpillar Dealer - Contact your Caterpillar dealer to schedule a Before Failure Overhaul. Overhaul Kit - This useful kit was developed for those users that prefer to perform their own overhaul. This kit includes a combination of new, reused and Remanufactured parts. Also included is a step-by-step instruction regarding how to perform an overhaul. An Overhaul Kit simplifies parts ordering, helps speed repairs and reduces parts costs. Contact your local Caterpillar dealer for information regarding the Overhaul Kit.Overhaul Recommendation
Overhaul programs vary from dealer to dealer. Therefore, Caterpillar recommends that you confer with your dealer to obtain specific information regarding the types of programs offered and overhaul services provided for extending the life of your engine.After Failure Overhaul
If you experience a major engine failure which requires removal of the engine, there are also many After Failure Overhaul options available. An overhaul should be performed if your block or crankshaft needs to be repaired. If the block and/or crankshaft is repairable, then the cost of an overhaul should be between 40 and 50% of the cost of a new engine (with like exchange core).This lower cost can be attributed to Caterpillar "designed-in" features that include regrindable crankshaft, undersize bearings, if needed and Cat dealer and Caterpillar Remanufactured exchange components.
Your Caterpillar dealer may be offering a variety of options regarding overhaul programs and Caterpillar recommends that an Overhaul be performed at this maintenance interval.Overhaul Options
Caterpillar Dealer - Contact your Caterpillar dealer to schedule a Before Failure Overhaul. Overhaul Kit - This useful kit was developed for those users that prefer to perform their own overhaul. This kit includes a combination of new, reused and Remanufactured parts. Also included is a step-by-step instruction regarding how to perform an overhaul. An Overhaul Kit simplifies parts ordering, helps speed repairs and reduces parts costs. Contact your local Caterpillar dealer for information regarding the Overhaul Kit.Overhaul Recommendation
Overhaul programs vary from dealer to dealer. Therefore, Caterpillar recommends that you confer with your dealer to obtain specific information regarding the types of programs offered and overhaul services provided for extending the life of your engine.After Failure Overhaul
If you experience a major engine failure which requires removal of the engine, there are also many After Failure Overhaul options available. An overhaul should be performed if your block or crankshaft needs to be repaired. If the block and/or crankshaft is repairable, then the cost of an overhaul should be between 40 and 50% of the cost of a new engine (with like exchange core).This lower cost can be attributed to Caterpillar "designed-in" features that include regrindable crankshaft, undersize bearings, if needed and Cat dealer and Caterpillar Remanufactured exchange components.
Have questions with 101606-1521?
Group cross 101606-1521 ZEXEL
Mitsubishi
101606-1521
F 01G 09U 04E
ME076014
INJECTION-PUMP ASSEMBLY
6D15
6D15