106861-2640 ZEXEL 9 400 618 003 BOSCH INJECTION-PUMP ASSEMBLY 9400618003 1068612640 me441199

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 003 9400618003

ZEXEL 106861-2640 1068612640

MITSUBISHI ME441199 me441199

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Buy INJECTION-PUMP ASSEMBLY 106861-2640 zexel genuine, new aftermarket engine parts with delivery

Service parts 106861-2640 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106086-5740

3. GOVERNOR 105487-7740

4. SUPPLY PUMP 105237-5580

5. AUTOM. ADVANCE MECHANIS 105681-2810

6. COUPLING PLATE 105663-0390

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4972

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105030-4990

14. NOZZLE

105015-4580

15. NOZZLE SET

Include in #1:

106861-2640 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 003 9400618003

ZEXEL 106861-2640 1068612640

MITSUBISHI ME441199 me441199

Zexel num

Bosch num

Firm num

Name

106861-2640

9 400 618 003

ME441199 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9T K 14CD INJECTION PUMP ASSY PE8P 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 131424-4620

Overflow valve opening pressure kPa 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

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 1-2-7-3- 4-5-6-8

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 9.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 137.5 134.5 140.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.3+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12 9.4 14.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 200 200 200

Average injection quantity mm3/st. 205 185 225

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1100++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1100.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 3.5 3.5 3.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (5)Damper spring setting
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RT=1 TH=2.9mm SXL=9.8+-0.1mm
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Speed control lever angle

F:Full speed
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----------
a=(13.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=31deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Drive side (3)- (4)Rack position = bb, set the stopper bolt.
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aa=32mm bb=3.5-0.5mm
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a=10.5deg+-5deg b=57.5deg+7deg-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325r/min Ra=6+-0.1mm
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0000001601 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
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V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
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Timing setting

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

----------
a=(40deg)

Information:

Crankshaft Grinding Specifications
The dimensions and finish for grinding crankshafts are as follows:Diameter (A) for connecting rod bearing journals is;.010 in. (0.25 mm) Undersize ... 2.7396 .0006 in.(69.586 0.015 mm).020 in. (0.51 mm) Undersize ... 2.7296 .0006 in.(69.332 0.015 mm).050 in. (1.27 mm) Undersize ... 2.6996 .0006 in.(68.570 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (B) must be .100 .010 in. (2.54 0.25 mm).Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.
DIMENSIONS FOR GRINDING
A. Diameter of connecting rod bearing journals. B. Radius on connecting rod bearing journals. C. Width to grind journals for the connecting rods. D. Diameter of main bearing journals. E. Radius on main bearing journals. F. Width to grind journals for the main bearings.Width (C) is 2.314 .003 in. (58.77 0.08 mm)Diameter (D) for main bearing journals is:.010 in. (0.25 mm) Undersize ... 3.4895 .0006 in.(88.633 0.015 mm).020 in. (0.51 mm) Undersize ... 3.4795 .0006 in.(88.379 0.015 mm).050 in. (1.27 mm) Undersize ... 3.4495 .0006 in.(87.617 0.015 mm)Surface finish must be 10 micro inches (0.25 micrometers) or less.Radius (E) must be .095 .010 in. (2.41 0.25 mm)Surface finish must be 63 micro inches (1.6 micrometers) or less.The radius must blend smoothly with the newly machined journals.Width (F) is 1.258 .002 in. (31.95 0.05 mm) for number 4 main bearing journal. Surface finish on the thrust faces of the number 4 main must be 18 micro inches (0.45 micrometers) or less.Width (F) is 1.268 + .020 - .010 in. (32.21 + 0.51 - 0.25 mm) for number 2, 3, and 5 main bearing journals.There is no width (F) for number 1 main bearing journal.When grinding a crankshaft, no material can be removed from the crankshaft webs or counterweights.Crankshaft Gear Removal
Remove the gear using an 8B7548 Push Puller, 8B7551 Bearing Pulling Attachment, 8B75621 Step Plate, and 8H684 Ratchet Box Wrench.
PULLING CRANKSHAFT GEARThe 1P820 Hydraulic Puller Group can also be used to pull gear from crankshaft. Tools required are 1P820 Hydraulic Puller Group, 8B7551 Bearing Pulling Attachment, 8B7549 Puller legs (two), 8B7561 Step Plate, 3H465 Plate (four), 1B4207 Nut (two), and 5P3100 Pump Group.
USING HYDRAULIC PULLERCrankshaft Gear Installation
1. Install the key in keyway of crankshaft. Remove all burrs from key and keyway inside of crankshaft gear.2. Heat gear to 500°F (260°C) maximum.3. Install gear on crankshaft with timing mark on gear facing front of crankshaft.Crankshaft Front Oil Seal Removal
Remove the crankshaft front pulley. Use the 1P3075 Puller Group to remove the crankshaft front oil seal.
REMOVING FRONT OIL SEAL (Typical Example)Remove Crankshaft Rear Seal And Wear Sleeve
Remove the crankshaft rear oil seal with the 1P3075 Puller Group.
REMOVING REAR OIL SEALInstall a 5P7338 Distorter Ring from the 5P7318 Wear Sleeve Distorter Group, in the rear seal bore.
REMOVING REAR WEAR SLEEVE (Typical Example)Install 5P7312 Distorter between distorter ring and wear sleeve. Turn the distorter until the