106871-2740 ZEXEL 9 400 618 099 BOSCH INJECTION-PUMP ASSEMBLY 9400618099 1068712740 me066693

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 099 9400618099

ZEXEL 106871-2740 1068712740

MITSUBISHI ME066693 me066693

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Service parts 106871-2740 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-5730

3. GOVERNOR 105306-0910

4. SUPPLY PUMP 105207-1140

5. AUTOM. ADVANCE MECHANIS 105636-1200

6. COUPLING PLATE 105663-0260

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7430

11. Nozzle and Holder ME6H6045A

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105031-4500

14. NOZZLE

105015-7310

15. NOZZLE SET

Include in #1:

106871-2740 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 099 9400618099

ZEXEL 106871-2740 1068712740

MITSUBISHI ME066693 me066693

Zexel num

Bosch num

Firm num

Name

106871-2740

9 400 618 099

ME066693 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9 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 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 1-2-7-3- 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 -

Rack position 9.5

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 118 114.5 121.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.5)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 118 117 119

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 124 118.8 129.2

Difference in delivery mm3/st. 10.4 10.4 10.4

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position 11.6+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 125 105 145

Fixing the lever *

Remarks
Rack limit using stop lever.

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_04

Pump speed r/min 1150

Advance angle deg. 6.5 6 7

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Rack limit using stop lever (2)Excess fuel setting for starting: SXL (3)Damper spring setting: DL
----------
SXL=R1+0.2mm DL=4.3-0.2mm
----------

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=16deg+-5deg b=18deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Using reverse lever (top)
----------

----------
a=(18deg)+-6deg b=(36deg)+-6deg

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=325+-5r/min Ra=5.6mm
----------

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:

Illustration 39 g00367353
Set the drive speed to "Col 4". Place a straight edge across the opening in the shutdown rod and the shutdown rod nut (F). Use a 7/16 inch open end wrench in order to turn the shutdown rod nut (F) counterclockwise until the governor begins to shut down. Once the governor begins to shut down, turn the nut clockwise one full turn.Adjustment Of The Shutdown Device
Note: The electric shutdown device and the pressure shutdown device should be checked prior to the installation, after the installation, and at 1000 hour intervals thereafter.
Failure to test, inspect and maintain these items could result in faulty operation and possible severe engine damage if an emergency shutdown situation occurs.
The electric shutdown is either an Energize-To-Shutoff (ETS) or an Energize-To-Run (ETR). Identify the type of shutdown device in your governor, and make a note of the type of shutdown device.
Visually inspect the pressure shutdown components for signs of burrs, nicks, scoring and/or wear. Repair the components if evidence of a problem exists. Inspect the pressure shutdown gasket. Determine if the gasket is reusable. If necessary, replace the gasket.
Illustration 40 g00367319
(F) Shutdown Rod Nut. (J) Shutdown Rod. (II) Solenoid. (JJ) Jam Nut. (KK) Set Screw. (LL) Shutdown Plunger. (MM) Solenoid Plunger. (NN) Pivot Pin. (PP) Shutdown Lever.
Visually inspect the electric shutdown device and determine if there is any component wear. If the shutdown is an ETS version, pay particular attention to the connection of the shutdown solenoid's plunger and the shutdown lever's link pin.If there is evidence of wear, replace the solenoid. Inspect the gasket on the electric shutdown. Determine if the gasket is reusable. If necessary, replace the gasket.Check the size of spacer on the solenoid plunger in the electric shutdown. Refer to the Service Magazine Article November 19,, "Field Replacement of Spacer to Correct Possible Sticking in Woodward 3161 Governor Electric Shutoff Group".Adjustment Of The Electric Shutdown Solenoid
Energize-To-Shutoff (ETS)
Place the housing of the electric shutdown in a vise. Use copper jaws or shop towels in order to protect the sides of the aluminum die cast housing. Do NOT excessively tighten the vise.Loosen the jam nut (JJ) that holds the solenoid in the electric shutdown's housing. Remove the solenoid coil (II) in order to expose the shutdown plunger (MM) .Note: Loctite 222 is used on the threads of the solenoid coil during manufacturing. In addition, the jam nut is tightened to a torque of 75 N m (55.5 lb ft).
Carefully clean any dirt, metal filings or metal chips from the solenoid plunger and from the cavity in the solenoid coil. Turn the jam nut on the solenoid coil so that the nut will not interfere with the adjustment of the solenoid coil. Reinstall the solenoid coil in the electric shutdown's housing by turning the coil four times.
Hold the housing and the gasket on a