101606-1921 ZEXEL 9 400 615 477 BOSCH INJECTION-PUMP ASSEMBLY 9400615477 1016061921 me076286


 

Information injection-pump assembly

BOSCH 9 400 615 477 9400615477
ZEXEL 101606-1921 1016061921
MITSUBISHI ME076286 me076286
101606-1921 INJECTION-PUMP ASSEMBLY
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Service parts 101606-1921 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101061-9170
3. GOVERNOR 105931-5290
4. SUPPLY PUMP 105210-4700
5. AUTOM. ADVANCE MECHANIS 105643-0410
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-7510
11. Nozzle and Holder ME076087
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}
13. NOZZLE-HOLDER 105030-4110
14. NOZZLE 105015-7440
15. NOZZLE SET

Include in #1:

101606-1921 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

BOSCH 9 400 615 477 9400615477
ZEXEL 101606-1921 1016061921
MITSUBISHI ME076286 me076286


Zexel num
Bosch num
Firm num
Name
101606-1921 
101607-1140 
9 400 615 477 
ME076286  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D16 * 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   3.5 3.45 3.55
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   11.1
Pump speed r/min   850 850 850
Each cylinder's injection qty mm3/st.   68 66 70
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.   8.7 8.2 9.2
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.1)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   68 67 69
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.2
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   79.9 75.9 83.9
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   D
Rack position   R1+0.2
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   52.4 48.4 56.4
Fixing the lever   *
Injection quantity adjustment_06
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   *
Timer adjustment
Pump speed r/min   1150
Advance angle deg.   0.5
Timer adjustment_02
Pump speed r/min   1250
Advance angle deg.   2.5 2 3
Timer adjustment_03
Pump speed r/min   1350
Advance angle deg.   5 4.5 5.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101606-1921
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=D15
----------

Speed control lever angle

Test data 101606-1921
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=10deg+-5deg b=(46deg)+-3deg

Stop lever angle

Test data 101606-1921
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).
----------
aa=1400r/min bb=(6.5)mm cc=275r/min dd=(6.5)mm
----------
a=11.5deg+-5deg b=(27deg)+-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=400r/min Ra=9.2+-0.1mm
----------

Timing setting

Test data 101606-1921
(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)




Information:

Heavy Duty Air Cleaners
Engines equipped with heavy duty air cleaners have a serviceable air cleaner element. The element may be cleaned up to six times, but must be replaced Every Year.Remove and Install Air Cleaner Elements
Heavy duty air cleaner:(1) service indicator(2) upper body (air filter element housing)(3) clamps(4) lower body (tube element)(5) dust collector cup1. Loosen clamps (3) between the lower body (4) and the dust collector cup (5). Remove the cup.2. Loosen the clamps between the lower body and the upper body (2). Remove the tube element.3. Clean the tubes from both sides with water or air.4. Remove the air filter element from the upper body (2). Wipe the inside of the upper body clean.5. Inspect and clean air filter element. Install a clean or new element.6. Inspect the gasket between the upper body and lower body. Inspect the seal between the lower body and the dust collector cup. Install a new gasket and seal if necessary.7. Install the cleaned, dry tube element. Tighten the retaining clamps attaching the lower body to the upper body.8. Wipe the dust collector cup clean. Install the cup and tighten the retaining clamps.9. Reset the service indicator (1).Cleaning Air Filter Elements
The primary element (Caterpillar air filters) can be cleaned several times before replacement. The element, when cleaned, should be thoroughly checked for rips or tears in the filter material.Replace the primary element at least EVERY YEAR regardless of operating hours it has accumulated.
Do not clean filter elements by bumping or tapping.Do not use filter elements with damaged pleats, gaskets or seals. Engine damage could result.
Filter elements can be cleaned with air pressure, 205 kPa (30 psi) maximum, or water pressure, 280 kPa (40 psi) maximum, or detergent washing. Have spare elements on hand to use while cleaning used elements.* Direct air or water along the length of the plate inside and outside of air filter element.The element can be washed in warm water and nonsudsing household detergent, such as automatic dishwasher detergent. Rinse inside and outside the pleats. The filter should then be thoroughly air dried and inspected.* Inspect the filter elements after cleaning for any rips, tears or damage. Insert a light inside of the clean, dry element. Do not use a filter element with damaged pleats, gaskets or seals. Discard the element if damaged.* Wrap and store the clean filter elements in a clean, dry place.* Reset the service indicator by pushing the piston plunger in.For more information on air cleaner element cleaning, refer to Guideline for Reusable Parts-Cleaning and Inspection of Air Filters, SEBU8062.Air Starter & Air Tank (If Equipped)
Check Lubricator Level
Never allow the lubricator bowl (if equipped) to become empty. The starting motor will be damaged by lack of proper lubrication.
The vanes of the starting motor are lubricated with a fine mist of oil from the motor lubricator. Check the level of oil in the lubricator bowl. If the bowl is less than half full, add lubricant. Use non detergent 10W engine oil for temperatures that are

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