101606-1912 ZEXEL 9 400 615 476 BOSCH INJECTION-PUMP ASSEMBLY 9400615476 1016061912 me076284


 

Information injection-pump assembly

BOSCH 9 400 615 476 9400615476
ZEXEL 101606-1912 1016061912
MITSUBISHI ME076284 me076284
101606-1912 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 400 615 476 9400615476
ZEXEL 101606-1912 1016061912
MITSUBISHI ME076284 me076284


Zexel num
Bosch num
Firm num
Name
101606-1912 
9 400 615 476 
ME076284  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D15T2 * 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   -
Rack position   12.9
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   90.8 88.1 93.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   H
Rack position   9.5+-0.5
Pump speed r/min   275 275 275
Each cylinder's injection qty mm3/st.   10.2 8.7 11.7
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.9)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   90.8 89.8 91.8
Basic   *
Fixing the lever   *
Boost pressure kPa   38.7 38.7
Boost pressure mmHg   290 290
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.15
Pump speed r/min   1350 1350 1350
Average injection quantity mm3/st.   104 100 108
Fixing the lever   *
Boost pressure kPa   38.7 38.7
Boost pressure mmHg   290 290
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.7
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   97.8 93.8 101.8
Fixing the lever   *
Boost pressure kPa   38.7 38.7
Boost pressure mmHg   290 290
Injection quantity adjustment_06
Adjusting point   D
Rack position   R2-1.5
Pump speed r/min   350 350 350
Average injection quantity mm3/st.   59 55 63
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_07
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   85 65 105
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   350 350 350
Rack position   R2-1.5
Boost pressure kPa   8 8 8
Boost pressure mmHg   60 60 60
Boost compensator adjustment_02
Pump speed r/min   350 350 350
Rack position   R2-1.2
Boost pressure kPa   12.7 11.4 14
Boost pressure mmHg   95 85 105
Boost compensator adjustment_03
Pump speed r/min   350 350 350
Rack position   R2(R1+0. 7)
Boost pressure kPa   25.3 25.3 25.3
Boost pressure mmHg   190 190 190
Timer adjustment
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1225
Advance angle deg.   1.5 1 2
Timer adjustment_03
Pump speed r/min   1300
Advance angle deg.   3 2.5 3.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101606-1912
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=E33 BCL=1.5+-0.1mm
----------

Speed control lever angle

Test data 101606-1912
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=10deg+-5deg b=47deg+-3deg

Stop lever angle

Test data 101606-1912
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee.
----------
aa=1350r/min bb=6.5-0.5mm cc=275r/min dd=(8.5)mm ee=17.4mm
----------
a=38.5deg+-5deg b=19deg+-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=9.2mm
----------

Timing setting

Test data 101606-1912
(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=11deg
----------
a=(1deg)




Information:

Adjust - to conform and correspond to specifications. Check - to observe for satisfactory conditions, accuracy, safety or performance. Exchange - to trade a worn or failing component for a remanufactured or rebuilt component. Inspect - to examine closely, in critical appraisal, while testing or evaluating components or systems. Inspect/Rebuild or Exchange - to examine closely, then making the decision on repair option (i.e. Rebuild or Exchange). Lubricate - to apply a lubricant (oil, grease, etc.) as specified for reducing friction, heat and wear between solid surfaces. Protective Devices - indicators such as gauges, lights, emergency shutoffs, etc., that alert an operator that a potential problem may exist. Failure to respond to these indicators in a timely manner could result in serious engine damage. Rebuild - to repair worn or failing component with new parts, components and/or remanufactured components. Replace - to install something new, remanufactured or rebuilt in place of an existing worn or failing component. Service Hours (Electrical) - records the time (clock hours) the engine is actually running but does not reflect variations in speed, load, etc. Some engines are equipped with mechanical service meters reading in Service Meter Units (SMU). The Maintenance Schedules are developed for clock hours or fuel consumption. For most users, clock hours are the standard interval for maintenance and SMU's can be roughly equal to clock hours. However, Caterpillar recommends that fuel consumption be used as the preferred method of determining intervals rather than SMU's or clock hours.Interval Categories
Engine components can generally be grouped into speed sensitive and load sensitive categories. The maintenance interval for each item listed in the Maintenance Schedule is based on either engine speed or load. Speed sensitive items such as water pumps an air compressors are not primarily affected by the operating load on your engine. The load on an engine will not significantly accelerate the repair or replacement cycle for speed sensitive items. The maintenance intervals established for speed sensitive items are based on service hours. Load sensitive items such as piston rings and cylinder liners are affected by the operating load on your engine. Generally speaking, the lower the load, the longer the engine life. Conversely, the higher the load, the shorter the engine life. A heavy load on an engine will accelerate the repair or replacement cycle for load sensitive items.Load sensitive items are normally internal engine components. The amount of fuel consumed is directly related to the load on your engine.The maintenance interval for load sensitive items includes fuel consumption, since the amount of fuel consumed is directly related to the load on your engine.Caterpillar recommends performing maintenance on load sensitive items at maintenance intervals based on the quantity of fuel consumed.

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