Information injection-pump assembly
BOSCH
9 400 615 651
9400615651
ZEXEL
101607-1891
1016071891
MITSUBISHI
ME076868
me076868
Rating:
Cross reference number
BOSCH
9 400 615 651
9400615651
ZEXEL
101607-1891
1016071891
MITSUBISHI
ME076868
me076868
Zexel num
Bosch num
Firm num
Name
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
131424-8420
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
3.2
3.15
3.25
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
11.7
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
77.8
75.5
80.1
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
9.5+-0.5
Pump speed
r/min
800
800
800
Each cylinder's injection qty
mm3/st.
10.8
9.2
12.4
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.7)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
77.8
76.8
78.8
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.6
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
89.9
85.9
93.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
56.3
52.3
60.3
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
91
81
101
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1100--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1050
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
----------
T1=G75
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----------
T1=G75
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Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18.5deg+-5deg b=41deg+-3deg
----------
----------
a=18.5deg+-5deg b=41deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
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.
(4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg
0000001501 LEVER
(A) Accelerator lever stopper bolt
(B) Link
(c) Nut
(D) Lever
(E) Pin
(f) lever
(G) Stopper bolt
(H) Return spring
(J) Pin (E) contacts lever.
(K) Load sensor terminal
(1)Black
(2)Blue-yellow
(3)Blue-red
Setting the accelerator lever angle, load sensor adjustment
1. Accelerator lever setting method
(1)Position the speed lever against the idle stopper bolt and fix.
(2)Screw in the accelerator lever stopper bolt (A) and back off the stopper bolt (A) from the position where the accelerator lever pin contacts the speed lever and set. (Gap: approx. 1 mm)
Tightening torque: 4.9~7 N.m {0.5~0.7 kgf.m}
2. Load sensor adjustment (See fig 1)
(1)Load sensor output measuring circuit
Apply DC5+-0.01V to the load sensor terminals and measure the output voltage.
(2)Load sensor output adjustment procedure
Hold the speed lever against the full side stopper bolt and fix. Adjust the load sensor output voltage to VF = 0.417+-0.1 V using the link (B) and then fix temporarily using nut (C).
Turn the speed lever from the idle side to the full side and confirm that output voltage VF = 0.417+-0.1 V is obtained. Confirm several times and then fix using nut (C).
Tightening torque: 3.4~4.9 N.m {0.35~0.5 kgf.m}
3. Setting the step motor's idle side stopper bolt
After adjustment in previous 1 and 2, position speed lever against idle stopper bolt and fix. Then, screw in stopper bolt G until step motor lever D's pin E contacts lever F. Back off 10+2 deg (approx. 3.5 mm) from this position and fix G. (See fig. 3)
4. Speed lever return confirmation
(1)Remove return spring (H) and confirm that the speed lever is returned to the idle position by the torsion spring.
(2)Reinstall the return spring (H) in its original position.
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----------
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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=10deg
----------
a=(3deg)
----------
aa=10deg
----------
a=(3deg)
Information:
Illustration 1 g00564355
7W-2743 Electronic Speed Switch (ESS)
(1) Push button for Overspeed Verification
(2) Reset button
(3) Overspeed indicator lamp
(4) Seal screw plug for adjusting the engine overspeed
(5) Seal screw plug for adjusting the crank terminate speed
(6) Seal screw plug for adjusting the oil step pressure speed setting The overspeed calibration can increase the overspeed setting or the overspeed calibration can decrease the overspeed setting in order to shut down the engine when the overspeed verification button is pressed. The overspeed setting is correctly made when the engine is running at 75% of the overspeed setting. The engine then shuts down when the overspeed verification button is pressed.Use the following procedure in order to adjust the overspeed setting.
Remove the lockwire and the seal from seal screw plug (4). Remove seal screw plug (4) from the access hole for the overspeed adjustment screw.
Use a small screwdriver to lightly turn the overspeed adjustment screw in the direction of the "MAX" arrow or the clockwise direction. Turn the screw 20 times. The overspeed adjustment screw will vary the setting of a potentiometer that is inside of the ESS. The overspeed adjustment screw will not cause damage to the potentiometer. Also, the screw can not be removed if the screw is turned in the wrong direction.
Run the engine at 75% of the desired overspeed setting rpm. Refer to the Speed Specification Chart.
While the engine is running at 75% of the overspeed setting rpm, press "VERIFY" button (1). While the button is depressed, slowly turn the overspeed adjustment screw in the opposite direction of the "MAX" arrow or the counterclockwise direction until overspeed indicator lamp (3) is lighted. The engine will shut down if the ESS is connected to the fuel shutoff solenoid (FSOS) and the air shutoff solenoid, if equipped.
In order to reset the ESS, press "RESET" button (2). The air shutoff valve must be reset by hand, if equipped.
Slowly turn the overspeed adjustment screw in the clockwise direction for one turn. Repeat Steps 3, 4, and 5. More adjustment may be necessary in order to gain the correct setting. Turn the overspeed adjustment screw in the clockwise direction in order to increase the overspeed setting. Turn the overspeed adjustment screw in the counterclockwise direction in order to decrease the overspeed setting.
When the overspeed setting is correct, install seal screw plug (4) in the access hole for the overspeed adjustment screw. Tighten the screw to a torque of 0.20 0.03 N m (1.8 .3 lb in). Install the lockwire and the seal if the calibration of the crank termination speed and the oil step speed calibration are also complete.