106491-4003 ZEXEL 9 400 616 529 BOSCH INJECTION-PUMP ASSEMBLY 9400616529 1064914003 3636520130

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 616 529 9400616529

ZEXEL 106491-4003 1064914003

MITSUBISHI-HEAV 3636520130 3636520130

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Service parts 106491-4003 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106049-5022

3. GOVERNOR 105407-7170

4. SUPPLY PUMP 105217-1331

5. AUTOM. ADVANCE MECHANIS 105681-2510

6. COUPLING PLATE 105662-0730

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6290

11. Nozzle and Holder 3636100040

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105030-4180

14. NOZZLE 105015-8630

15. NOZZLE SET

Include in #1:

106491-4003 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 529 9400616529

ZEXEL 106491-4003 1064914003

MITSUBISHI-HEAV 3636520130 3636520130

Zexel num

Bosch num

Firm num

Name

106491-4003

9 400 616 529

3636520130 MITSUBISHI-HEAV

INJECTION-PUMP ASSEMBLY
S4BB2 K 14BW INJECTION PUMP ASSY PE4P,4PD 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 8-3-600

Overflow valve 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.7 3.65 3.75

Beginning of injection position
Governor 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 9.8

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 125 120 130

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 4.9+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 18 15 21

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 10++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 225 225 235

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 570--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 520

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
K=15
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Stopper bolt setting
----------

----------
a=5deg+-5deg b=32deg+-3deg c=22deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=50deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(10deg)

Information:

Typical Example1. Remove bolts (1) from the alternator bracket.2. Remove the bolts that hold plate (3) and remove the plate.3. Disconnect water line (2) from the air compressor. Turn the water line tee toward the lifting bracket in order to provide clearance to remove the head bolt. 4. Remove bolts (4) and (5) that hold the cylinder head assembly to the cylinder block.5. Fasten a hoist and remove the cylinder head assembly. The weight is approximately 135 kg (300 lb).
Do not put the cylinder head assembly down on a flat surface. This can cause damage to the fuel injection valves.
6. Remove the gasket and seals from the spacer plate.Install Cylinder Head Assembly
Be sure a new gasket has been installed between the spacer plate and the cylinder block. See topic, "Remove & Install Spacer Plate". 1. Thoroughly clean the spacer plate and the bottom surface of the cylinder head assembly. Install a new head gasket, new seals (1) and two O-ring seals (2). 2. Fasten a hoist and put the cylinder head assembly (3) in position on the cylinder block.3. Tighten the bolts in sequence shown in Illustration D11970.
(1) Large bolts (3/4 inch). Put 6V4876 Molycoat Paste Lubricant on bolt threads and between washers and underside of bolt heads.(2) Small bolts (3/8 inch). See Step 4h.4. Install the cylinder head bolts and washers. Tighten the bolts in sequence shown.a. Tighten bolts 1 through 14 in number sequence to 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).c. Tighten bolts 1 through 14 in number sequence again to 470 20 N m (345 15 lb ft).d. Install the rocker arm shafts for the engine valves and the remaining (3/4 in) bolts and/or compression brake studs.e. Tighten bolts 15 through 26 in number sequence to 270 25 N m (200 20 lb ft).f. Tighten bolts 15 through 26 in number sequence to 450 20 N m (330 15 lb ft).g. Tighten bolts 15 through 26 in number sequence again to 450 20 N m (330 15 lb ft).h. Tighten the thirteen small bolts (2) to 45 7 N m (33 5 lb ft).5. Make an adjustment to the valves to have a clearance of 0.38 mm (.015 in) for intake and 0.76 mm (.030 in) for exhaust. Tighten the locknuts for the valve adjustment screws to a torque of 28 4 N m (21 3 lb ft).6. Install the valve cover bases and the inner fuel lines. See topic, "Install Rocker Shaft Assemblies & Push Rods".7. Install the valve covers. See topic, "Install Valve Covers".
Typical Example8. Install plate (4).9. Connect the water line to the air compressor.10. Install bolts (5) for the alternator bracket.End By:a. install exhaust manifoldb. install fuel injection linesc. install aftercooler housingd. install water temperature regulatore. install rocker shaft assemblies and push rods