Information injection-pump assembly
BOSCH
9 400 618 204
9400618204
ZEXEL
106871-7290
1068717290
MITSUBISHI
ME065914
me065914
Rating:
Service parts 106871-7290 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Include in #1:
106871-7290
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 618 204
9400618204
ZEXEL
106871-7290
1068717290
MITSUBISHI
ME065914
me065914
Zexel num
Bosch num
Firm num
Name
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 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
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
-
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
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
155
135
175
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
550--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Excess fuel setting for starting: SXL
(4)Damper spring setting: DL
----------
RT=1 TH=2.2mm SXL=10.2+-0.1mm DL=4.3-0.2mm
----------
----------
RT=1 TH=2.2mm SXL=10.2+-0.1mm DL=4.3-0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=21deg+-5deg
----------
----------
a=21deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=26deg+-3deg
----------
----------
a=10deg+-5deg b=26deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Rack position = aa
(2)Stopper bolt setting
(3)Rack position bb
(4)Free (at shipping)
----------
aa=4-0.5mm bb=11.7mm
----------
a=43deg+7deg-5deg b=21.5deg+-5deg c=(10.5deg)
----------
aa=4-0.5mm bb=11.7mm
----------
a=43deg+7deg-5deg b=21.5deg+-5deg c=(10.5deg)
0000001501 ACS
Aneroid compensator adjustment
(1)Adjust the clearance between the aneroid compensator's main body and the push rod to L1.
(2)Pump speed N1 at load lever's full position.
(3)Screw in the aneroid compensator body to obtain the performance shown in the graph above.
----------
L1=0.1~0.5mm N1=700r/min
----------
Ra=9.5mm Rb=9.1mm P1=(97.3)kPa((730)mmHg) P2=84.6+-0.7kPa(635+-5mmHg) Q1=118+-1cm3/1000st Q2=108.6+-3cm3/1000st
----------
L1=0.1~0.5mm N1=700r/min
----------
Ra=9.5mm Rb=9.1mm P1=(97.3)kPa((730)mmHg) P2=84.6+-0.7kPa(635+-5mmHg) Q1=118+-1cm3/1000st Q2=108.6+-3cm3/1000st
0000001601 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
----------
----------
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)
----------
----------
a=(40deg)
Information:
start by:a) remove pistons 1. Remove bearings (3) from the connecting rod and connecting rod cap.2. Remove retainer ring (1) with tool (A).3. Remove pin (2) and connecting rod (4) from the piston. 4. Remove the piston rings (5) from the piston with tool (B). Clean the piston ring grooves on the pistons with an acceptable ring groove cleaning tool. See USE OF PISTON PIN BEARING REMOVAL AND INSTALLATION TOOLS, SPECIAL INSTRUCTIONS, Form No. SMHS7295.5. Heat the connecting rod (4) in an oven to a temperature of 350°-500°F (177°-260°C). Never use a direct flame to heat a connecting rod. 6. Put connecting rod (4) in position on the base plate of tooling (C). Put a new rod pin bearing (6) on the adapter part of tooling (C). The old bearing is pushed out by tooling (C) as the new bearing is installed.7. Use tooling (C) to push the new bearing into the connecting rod until the push adapter of tooling (C) makes full contact with the connecting rod surface.8. Use a pin boring machine to make the rod pin bearing the correct size. The bore in the new rod pin bearing must be 2.0012 .0003 in. (50.830 0.008 mm).9. Check the clearance between the ends of the piston rings. See PISTONS AND RINGS in SPECIFICATIONS.10. Install the oil ring spring in the oil ring groove of the piston. The oil ring is to be installed over the spring with the oil ring end gap 180° from the oil ring spring joint. 11. Install the oil ring on the piston with tool (B).12. Install the second (intermediate) piston ring with the side that has the identification "UP-2" toward the top of the piston with tool (B).13. Install the first (top) piston ring with the side that has the identification "UP-1" toward the top of the piston with tool (B). After the installation of all three piston rings, put the piston rings in position so the end gaps are 120° apart. 14. Put the piston in position on connecting rod (4). Put clean engine oil on pin (2) and install the pin. Install retainer rings (1) with tool (A). Make sure the retainer rings are in the grooves of the piston.15. Install bearings (3) in the connecting rod and connecting rod cap.end by:a) install pistons