101608-6292 ZEXEL F 019 Z20 018 BOSCH INJECTION-PUMP ASSEMBLY f019z20018 1016086292 me440070

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 018 f019z20018

ZEXEL 101608-6292 1016086292

MITSUBISHI ME440070 me440070

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Buy INJECTION-PUMP ASSEMBLY 101608-6292 zexel genuine, new aftermarket engine parts with delivery

Service parts 101608-6292 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6730

3. GOVERNOR 105411-2262

4. SUPPLY PUMP 105210-5451

5. AUTOM. ADVANCE MECHANIS 105680-9000

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-5190

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7(180)

13. NOZZLE-HOLDER 105030-3660

14. NOZZLE 105025-3250

15. NOZZLE SET

Include in #1:

101608-6292 as INJECTION-PUMP ASSEMBLY

Include in #2:

104748-0482 as _

Cross reference number

BOSCH F 019 Z20 018 f019z20018

ZEXEL 101608-6292 1016086292

MITSUBISHI ME440070 me440070

Zexel num

Bosch num

Firm num

Name

101608-6292

F 019 Z20 018

ME440070 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D16TL K 14BN INJECTION PUMP ASSY 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 131424-5520

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 4.5 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 A

Rack position 11.5

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 116 115 117

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Boost pressure kPa 54.7 54.7

Boost pressure mmHg 410 410

Injection quantity adjustment_02

Adjusting point C

Rack position 8.1+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 8.5 7 10

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point E

Rack position 11.7++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 95 95 105

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position 9.5

Boost pressure kPa 15.3 8.6 22

Boost pressure mmHg 115 65 165

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position 10.7

Boost pressure kPa 45.3 42.6 48

Boost pressure mmHg 340 320 360

Timer adjustment

Pump speed r/min 1070--

Advance angle deg. 0 0 0

Load 4/4

Remarks
Beginning of advance.

Timer adjustment_02

Pump speed r/min 440

Advance angle deg. 3 2.5 3.5

Load 0/4

Remarks
Start

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0 0 0

Load 0/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1020

Advance angle deg. 0.5

Load 4/4

Timer adjustment_05

Pump speed r/min 1330

Advance angle deg. 3 2.5 3.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Boost compensator stroke: BCL (6)Main spring setting (7)Rack difference between N = N1 and N = N2
----------
K=11 BCL=1.2+-0.1mm N1=1400r/min N2=650r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Base lever only
----------

----------
a=(17deg)+-5deg b=(34deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=4-0.5mm
----------
a=28deg+-5deg b=(48deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A) After adjusting the boost compensator, tighten the bolts to remove the heads. (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=6.5deg
----------
a=(3deg)

Information:

AFFECTED PRODUCT
Model Identification Number
D6R III GMT00101-00170
HCD00123-00155
TBC00100-00191
D6R III LGP DMK00130-00208
JWD00250
LGP00164-00166
WRG00158-00564
D6R III XL GJB00173-00622
JDL00113-00202
LAE00125
LFM00111-00180
D6R III XW DPS00120-00132
MRT00163-00387
D6R IIIP LGP DLM00161-00162
WCB00112-00184
D6R IIIP XL HKE00146-00221
RFC00140
D6R IIIP XW DJG00250-00251
HDC00133-00211
MTJ00151-00152
PARTS NEEDED
No parts needed for this program
ACTION REQUIRED
Please refer to the attached Rework Procedure.
OWNER NOTIFICATION
U.S. and Canadian owners will receive the attached Owner Notification.
SERVICE CLAIM ALLOWANCES
Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
100% 100% 0% 0% 0% 0%
This is a 1.0-hour job
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
COPY OF OWNER NOTIFICATION FOR U.S. AND CANADIAN OWNERS
XYZ Corporation
3240 Arrow Drive
Anywhere, YZ 99999
PRIORITY - PRODUCT IMPROVEMENT PROGRAM FOR FLASHING INJECTOR ETRIM FILES
MODELS INVOLVED - CERTAIN D6R III, D6R IIIP XW, D6R IIIP LGP, D6R III LGP, D6R III XW, AND D6R III XL TRACK TYPE TRACTORS
Dear Caterpillar Product Owner:
New injector etrim files need to be installed on the products listed below. The upgraded files will help performance and stability of your D6R engine. You will not be charged for the service performed.
Contact your local Caterpillar dealer immediately to schedule this service. The dealer will advise you of the time required to complete this service.
Please refer the dealer to their Service Letter dated 31Aug2006 when scheduling this service.
We regret the inconvenience this may cause you, but urge you to have this service performed as soon as possible to prevent unscheduled downtime.
Caterpillar Inc.
Identification #(s)
Attached to 31Aug2006 Service Letter
Rework Procedure
Field Rework Procedure
1. Using the provided machine serial number of the D6R Series III tractor in your service area, go to TMI web and look up the engine serial number.
2. Look up your engine serial number on the Excell file emailed to all machine TCs in order to access the injector serial numbers. If you don't have a copy of this file go the the Knowledge Network to get the file from the following web address: https://kn.cat.com/message.cfm?id=4388&parent=153301&type=Broadcast
3. Copy the 6 injector serial numbers for each machine in your service area and go to SIS web.
4. At the main menu click on Service Software Files.
5. Follow the directions and down load the trim file for each injector, putting them on a disk or in a file that can be accessed from ET.
6. Down load the six trim files for the injectors and program into the ECM in the correct order, using ET.
7. Make sure the machine SN and /or engine SN are included in the service letter claim