101405-9491 ZEXEL 9 400 619 936 BOSCH INJECTION-PUMP ASSEMBLY 9400619936 1014059491 3426104091


 

Information injection-pump assembly

BOSCH 9 400 619 936 9400619936
ZEXEL 101405-9491 1014059491
MITSUBISHI-HEAV 3426104091 3426104091
101405-9491 INJECTION-PUMP ASSEMBLY
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Service parts 101405-9491 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101040-4160
3. GOVERNOR 105411-2811
4. SUPPLY PUMP 105220-7090
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105119-4120
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 17.7{180}
13. NOZZLE-HOLDER 105048-4540
14. NOZZLE 105017-9370
15. NOZZLE SET

Include in #1:

101405-9491 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 936 9400619936
ZEXEL 101405-9491 1014059491
MITSUBISHI-HEAV 3426104091 3426104091


Zexel num
Bosch num
Firm num
Name
101405-9491 
9 400 619 936 
3426104091  MITSUBISHI-HEAV
INJECTION-PUMP ASSEMBLY
S4K-T K 14BD INJECTION PUMP ASSY PE4AD 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   131424-5720
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)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-3-4-2
Pre-stroke mm   3.5 3.45 3.55
Rack position
After adjusting injection quantity.
  R=A
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-3
deg.   90 89.5 90.5
Difference between angles 2
Cal 1-4
deg.   180 179.5 180.5
Difference between angles 3
Cyl.1-2
deg.   270 269.5 270.5
Injection quantity adjustment
Adjusting point   A
Rack position   10
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   129.5 128.5 130.5
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the rack   *
Boost pressure kPa   141 141
Boost pressure mmHg   1060 1060
Injection quantity adjustment_02
Adjusting point   C
Rack position   6+-0.5
Pump speed r/min   525 525 525
Average injection quantity mm3/st.   12 10.7 13.3
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_03
Adjusting point   E
Rack position   10.2++
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   115 115 125
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Rack limit   *
Boost compensator adjustment
Pump speed r/min   450 450 450
Rack position   R2-1.2
Boost pressure kPa   21.3 18.6 24
Boost pressure mmHg   160 140 180
Boost compensator adjustment_02
Pump speed r/min   450 450 450
Rack position   R2(10)
Boost pressure kPa   128 128 128
Boost pressure mmHg   960 960 960

Test data Ex:

Governor adjustment

Test data 101405-9491
N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)The torque control spring does not operate. (4)RACK LIMIT (5)Boost compensator stroke: BCL (6)Idle sub spring setting: L1.
----------
K=5 BCL=1.2+-0.1mm L1=6.2-0.5mm
----------

Speed control lever angle

Test data 101405-9491
F:Full speed I:Idle S:Stop (1)Set the pump speed at aa (2)Stopper bolt setting (3)When pump speed set at bb
----------
aa=925r/min bb=770r/min
----------
a=(4deg)+-5deg b=(12.5deg)+-5deg c=(4.5deg)+-5deg d=32deg+-3deg

Stop lever angle

Test data 101405-9491
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Speed = bb, rack position = cc (sealed at delivery) (3)Normal
----------
aa=25mm bb=0r/min cc=1-0.5mm
----------
a=21deg+-5deg b=(55deg)

0000001501 I/P WITH LOAD PLUNGER ADJ

Load plunger-equipped pump adjustment 1. Adjust the variation between cylinders and the injection quantity. 2. At Full point A, adjust the pre-stroke to the specified value. 3. After pre-stroke adjustment, reconfirm that the fuel injection quantity and the variation between cylinders is as specified.
----------

----------

Timing setting

Test data 101405-9491
(1)Pump vertical direction (2)Position of camshaft's key groove at No 1 cylinder's beginning of injection (3)After adjusting the injection quantity, adjust at rack position aa. (4)-
----------
aa=10mm
----------
a=(50deg)




Information:


Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components. Allow the engine to engine cool down before stopping. Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.
If the engine has been operating at high load, run at low idle for at least three minutes before stopping. This cool down will reduce and stabilize internal engine coolant and oil temperatures before stopping the engine.If the engine has been operating at low loads, run the engine at low idle for 30 seconds before stopping.Make sure the shutoff procedure is understood. Refer to the Stopping the Engine instructions in the Generator Set Control Panel topic in this publication. Use the following general guidelines for stopping the engine.1. Open the Main electrical circuit breaker/Remove load from engine.2. Move the governor control to no more than half engine speed. Run the engine for three to five minutes.3. Reduce the engine speed to low idle.4. The engine may be stopped by using the Woodward Governor (if equipped), the Mechanical Governor (if equipped), or the solenoid shutoff switch.Woodward Actuator (If Equipped)
If equipped with a Woodward Actuator, move the control lever upward or forward, depending on the installation. Hold the lever to the OFF or STOP position until the engine stops.Mechanical Governor Control
A manual shutoff lever is provided to shut off the fuel from the fuel injection pump and override the governor control. The manual shutoff lever is located on the side of the pump.The engine can be shut OFF by rotating and holding the manual shutoff lever in the clockwise (CW) direction. If equipped with a Mechanical Governor Control, to move control to the SHUT OFF position: pull upward on the vernier hand grip while pushing down on thumb button. This shutdown will only move the fuel control linkage (rack) to the FUEL-OFF position. This does not shut off the air inlet.Solenoid Shutoff
Move the Control Panel Engine Control Switch (ECS, if equipped) to the STOP position.After Stopping the Engine
1. Fill the fuel tank to prevent accumulation of moisture in the fuel.2. Check the coolant level. Maintain the cooling system to 13 mm (1/2 inch) from bottom of the fill pipe. If freezing temperatures are expected, allow the radiator and engine jacket water system to cool, then check the coolant for proper antifreeze protection. The cooling system must be protected against freezing to the lowest expected ambient (outside) temperature. Add the proper coolant and water mixture if necessary.3. Check the crankcase oil level. Maintain the oil level between the ADD and FULL marks in the FULL RANGE zone on the dipstick.4. Repair any leaks, perform minor adjustments, tighten loose bolts, etc. 5. Note the service hour meter reading. Perform periodic maintenance as instructed in the Maintenance Schedule.

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101405-9491  
9 400 619 936 
3426104091 
INJECTION-PUMP ASSEMBLY
S4K-T
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