Information injection-pump assembly
BOSCH
9 400 613 019
9400613019
ZEXEL
106861-2490
1068612490
MITSUBISHI
ME098623
me098623
Rating:
Service parts 106861-2490 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME066034
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
106861-2490
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 613 019
9400613019
ZEXEL
106861-2490
1068612490
MITSUBISHI
ME098623
me098623
Zexel num
Bosch num
Firm num
Name
9 400 613 019
ME098623 MITSUBISHI
INJECTION-PUMP ASSEMBLY
8DC9T * K 14CD PE8P PE
8DC9T * K 14CD PE8P PE
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-4620
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-2-7-3-
4-5-6-8
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
A
Rack position
13.2
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
181
178
184
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
5.3+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
18.5
15.9
21.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
12.7
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
174
170
178
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
0.8
Timer adjustment_04
Pump speed
r/min
-
Advance angle
deg.
3
2.5
3.5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Rack difference between N = N1 and N = N2
(4)Idle sub spring setting: L1.
----------
K=11 N1=900r/min N2=500r/min L1=3.5+0.2-0.3mm
----------
----------
K=11 N1=900r/min N2=500r/min L1=3.5+0.2-0.3mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=5deg+-5deg b=28deg+-5deg
----------
----------
a=5deg+-5deg b=28deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Right front
(2)Right rear
----------
----------
a=19deg+-5deg b=46deg+-5deg c=28deg+-5deg d=53deg+-5deg
----------
----------
a=19deg+-5deg b=46deg+-5deg c=28deg+-5deg d=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=(40deg)
----------
----------
a=(40deg)
Information:
Proper operation and maintenance are key factors in obtaining the maximum life and economy of the engine. Following the directions in this manual will lower operating costs.The time needed for the engine to reach the normal mode of operation is usually less than the time taken for a walk-around-inspection of the engine.After the engine is started and the cold low idle operation is completed, the engine can be operated at rated speed and low power. The engine will reach normal operating temperature faster when operated at rated speed and low power demand than when idled at no load. Typically the engine should be up to operating temperature in a few minutes.Governors and Actuators
Your engine may be equipped with a:* full-range governor* Woodward PSG Governor* Woodward 1724 Actuator* Woodward 524 Actuator
PSG Actuator
1724/524 ActuatorWoodward Governors/Actuators are usually electrically operated from a control panel. The application is usually an EPG power generator set. On standby gen sets the governor may be set to operate only at Full Load Speed.Change Engine Speed
If equipped with a control panel, a RAISE/LOWER switch or a speed setting potentiometer is used to adjust the operating speed.Starting, Operating and Stopping Engines Equipped with Control Panels
For all information regarding the generator control panel used for starting, operating and stopping the engine, refer to the Engine Protection Devices Generator Set Control Panel topic in this publication or Caterpillar SR4 Generators and Control Panels, SEBU6150. Additional information and programming instructions are provided in the Service Manual for your specific control panel.Mechanical Governors (If Equipped)
Governor Control LeverYour engine may be equipped with a full-range governor. Most other manufacturers' engines have min-max type governors that only govern at high and low idle to prevent the engine from overspeeding or dying. With the min-max governor, the position of the speed lever determines the amount of fuel delivered to the engine.With the full-range governor, the position of the speed lever sets engine speed and helps hold a constant speed independent of load which makes operation easier.The governor control motor is a 24 volt motor which allows for engine speed control from a remote location through a governor RAISE/LOWER switch. This governor control switch is used with the optional EMCP II. Always increase engine speed to high idle before applying load.For information regarding initial checks and adjustments, refer to the Service Manual or contact your Caterpillar dealer.Driven Equipment Without Load
1. Move the governor control lever to half engine speed.2. Interrupted starts put excessive stress on the drive train and waste fuel. To get the driven equipment in motion, engage the clutch smoothly, with no load on the equipment. This should result in a smooth, easy start without increasing the engine speed above low idle or slipping the clutch. For generator sets, move the governor control to high idle (full load) position (1800 rpm for 60 Hz and 1500 rpm for 50 Hz).3. Apply the load and check the gauges and equipment for proper operation. Begin operating the engine at low load. After normal oil pressure
Your engine may be equipped with a:* full-range governor* Woodward PSG Governor* Woodward 1724 Actuator* Woodward 524 Actuator
PSG Actuator
1724/524 ActuatorWoodward Governors/Actuators are usually electrically operated from a control panel. The application is usually an EPG power generator set. On standby gen sets the governor may be set to operate only at Full Load Speed.Change Engine Speed
If equipped with a control panel, a RAISE/LOWER switch or a speed setting potentiometer is used to adjust the operating speed.Starting, Operating and Stopping Engines Equipped with Control Panels
For all information regarding the generator control panel used for starting, operating and stopping the engine, refer to the Engine Protection Devices Generator Set Control Panel topic in this publication or Caterpillar SR4 Generators and Control Panels, SEBU6150. Additional information and programming instructions are provided in the Service Manual for your specific control panel.Mechanical Governors (If Equipped)
Governor Control LeverYour engine may be equipped with a full-range governor. Most other manufacturers' engines have min-max type governors that only govern at high and low idle to prevent the engine from overspeeding or dying. With the min-max governor, the position of the speed lever determines the amount of fuel delivered to the engine.With the full-range governor, the position of the speed lever sets engine speed and helps hold a constant speed independent of load which makes operation easier.The governor control motor is a 24 volt motor which allows for engine speed control from a remote location through a governor RAISE/LOWER switch. This governor control switch is used with the optional EMCP II. Always increase engine speed to high idle before applying load.For information regarding initial checks and adjustments, refer to the Service Manual or contact your Caterpillar dealer.Driven Equipment Without Load
1. Move the governor control lever to half engine speed.2. Interrupted starts put excessive stress on the drive train and waste fuel. To get the driven equipment in motion, engage the clutch smoothly, with no load on the equipment. This should result in a smooth, easy start without increasing the engine speed above low idle or slipping the clutch. For generator sets, move the governor control to high idle (full load) position (1800 rpm for 60 Hz and 1500 rpm for 50 Hz).3. Apply the load and check the gauges and equipment for proper operation. Begin operating the engine at low load. After normal oil pressure