Information injection-pump assembly
BOSCH
9 400 612 047
9400612047
ZEXEL
106681-4282
1066814282
MITSUBISHI-HEAV
35A6500250
35a6500250
Rating:
Service parts 106681-4282 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
35A61-00010
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106681-4282
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 612 047
9400612047
ZEXEL
106681-4282
1066814282
MITSUBISHI-HEAV
35A6500250
35a6500250
Zexel num
Bosch num
Firm num
Name
9 400 612 047
35A6500250 MITSUBISHI-HEAV
INJECTION-PUMP ASSEMBLY
S6A3-TA * K
S6A3-TA * K
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
105780-8130
Bosch type code
EFEP215A
Nozzle
105780-0050
Bosch type code
DN6TD119NP1T
Nozzle holder
105780-2090
Bosch type code
EFEP215
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Outer diameter - inner diameter - length (mm) mm 8-4-1000
Overflow valve
131424-3420
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
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
2.8
2.75
2.85
Rack position
Point A R=A
Point A R=A
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
A
Rack position
11.1
Pump speed
r/min
975
975
975
Average injection quantity
mm3/st.
310
301
319
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
160
160
Boost pressure
mmHg
1200
1200
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.2+-0.5
Pump speed
r/min
365
365
365
Average injection quantity
mm3/st.
19.5
16.5
22.5
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-2.75
Boost pressure
kPa
73.3
70.6
76
Boost pressure
mmHg
550
530
570
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(12)
Boost pressure
kPa
147
140.3
153.7
Boost pressure
mmHg
1100
1050
1150
Timer adjustment
Pump speed
r/min
-
Advance angle
deg.
0
0
0
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
4
3.5
4.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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)Boost compensator stroke: BCL
(4)Rack difference between N = N1 and N = N2
(5)Rack difference between N = N3 and N = N4
----------
K=25 BCL=2.75+-0.1mm N1=975r/min N2=750r/min N3=975r/min N4=500r/min
----------
----------
K=25 BCL=2.75+-0.1mm N1=975r/min N2=750r/min N3=975r/min N4=500r/min
----------
Speed control lever angle
F:Full speed
I:Idle
(1)At the center of the lever key groove
----------
----------
a=(3deg)+-5deg b=(33deg)+-5deg
----------
----------
a=(3deg)+-5deg b=(33deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Pump speed aa, rack position bb
----------
aa=0r/min bb=1-0.5mm
----------
a=33deg+-5deg b=(73deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=33deg+-5deg b=(73deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(110deg)
----------
----------
a=(110deg)
Information:
Before any service work is to be done on the fuel system the outer surface of the injection pump housing must be clean.
1. Remove cover assembly (1) from the pump housing. Remove the spring for the bypass valve. 2. Loosen bushing (2) from the pump housing with tool (A). Do not loosen screws (3) when removing or installing the pumps. If the levers are moved, the fuel pump adjustment will be changed.3. Remove the fuel injection pump from the pump housing. The sleeve on the plunger will slide off the lever as the pump is removed.Install Fuel Injection Pumps
1. Put fuel injection pump (1) in the bore of the pump housing.2. Sleeve (2) must be engaged with lever (3) when installed correctly.
If the levers (3) have been moved on the shaft, fuel pump adjustment must be made. (See TESTING AND ADJUSTING).
3. Tighten the bushing with tool (A) to a torque of 70 5 lb.ft. (95 7 N m). 4. Put the spring and bypass valve in place. Install the cover assembly on the pump housing. Be sure spring (4) is in position in the cover.Disassemble Fuel Injection Pumps
start by: a) remove fuel injection pumps1. Remove bushing (1) from bonnet (2).2. Remove ring (3) from the bonnet and barrel (7). Remove check valve (6) and spring (4) from the bonnet.3. Remove spring (8) and washer (5). Remove plunger (9) and sleeve (10). Keep the plunger and sleeve with their respective barrel for installation. Do not use plungers, sleeves or barrels with other plungers, sleeves or barrels.Assemble Fuel Injection Pumps
1. Install sleeve (4), plunger (5), spring (2) and washer (3) on barrel (1).
Make sure the sleeve is installed with the thin edge up.
Be sure the sleeve and plunger are installed in their original barrel. Make sure the large hole in the plunger is up.2. Install the check valve and spring in the bonnet. Connect the barrel and bonnet and install the ring. Install the bushing on the bonnet.end by: a) install fuel injection pumps