Information injection-pump assembly
BOSCH
9 400 618 219
9400618219
ZEXEL
106871-7592
1068717592
MITSUBISHI
ME090641
me090641
Rating:
Service parts 106871-7592 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME066499
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106871-7592
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 618 219
9400618219
ZEXEL
106871-7592
1068717592
MITSUBISHI
ME090641
me090641
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
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
-
Rack position
10.3
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
131.8
127.9
135.7
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
17.5
14.9
20.1
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.3)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
131.8
130.8
132.8
Basic
*
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
138.6
134.6
142.6
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Injection quantity adjustment_05
Adjusting point
D
Rack position
-
Pump speed
r/min
200
200
200
Average injection quantity
mm3/st.
116
96
136
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
E
Rack position
11.3
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
147.2
144.2
150.2
Fixing the lever
*
Rack limit
*
Injection quantity adjustment_07
Adjusting point
F
Rack position
R1+0.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
136.9
133.9
139.9
Fixing the lever
*
Boost pressure
kPa
29.3
29.3
Boost pressure
mmHg
220
220
Boost compensator adjustment
Pump speed
r/min
450
450
450
Rack position
9.3
Boost pressure
kPa
4
4
4
Boost pressure
mmHg
30
30
30
Boost compensator adjustment_02
Pump speed
r/min
450
450
450
Rack position
10.7
Boost pressure
kPa
12.7
11.4
14
Boost pressure
mmHg
95
85
105
Boost compensator adjustment_03
Pump speed
r/min
450
450
450
Rack position
(11.3)
Boost pressure
kPa
16
16
16
Boost pressure
mmHg
120
120
120
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
4
3.5
4.5
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)Boost compensator cancel stroke: BSL
(4)RACK LIMIT
(5)Damper spring setting: DL
(6)Boost compensator stroke
(7)Rack difference between N = N1 and N = N2
----------
RT=1 TH=2.6mm BSL=1.6mm DL=5.7-0.2mm N1=1100r/min N2=700r/min
----------
----------
RT=1 TH=2.6mm BSL=1.6mm DL=5.7-0.2mm N1=1100r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
----------
----------
a=15deg+-5deg
----------
----------
a=15deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=35deg+-3deg
----------
----------
a=10deg+-5deg b=35deg+-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=3.5-0.5mm bb=14.6mm
----------
a=47deg+7deg-5deg b=31.5deg+-5deg c=(10.5deg)
----------
aa=3.5-0.5mm bb=14.6mm
----------
a=47deg+7deg-5deg b=31.5deg+-5deg c=(10.5deg)
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=325+-5r/min Ra=5.7mm
----------
----------
N1=325+-5r/min Ra=5.7mm
----------
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 pistons1. Check to be sure that all coolant has been removed from the cylinder block.2. Put a cover over the crankshaft journals before liners are removed. 3. Install tool (A) and remove the cylinder liners. 4. Remove filler band (1) and O-ring seals (2) from the cylinder liners.Install Cylinder Liners
1. Clean the cylinder liners and cylinder block. 2. Install the liners (1) in the cylinder block without the O-ring seals and filler bands. See CYLINDER LINER PROJECTION in TESTING AND ADJUSTING. 3. Install tooling (A) and two 5/8" - 11 NC bolts 5 1/2 in. long. Tighten the bolts evenly to 50 lb.ft. (70 N m).4. Check the liner projection with tool (B) at four locations around the liner.5. Liner projection must be .0020 to .0056 in. (0.051 to 0.142 mm). Measurements on the same liner must not be different by more than .002 in. (0.05 mm). Average measurement between liners next to each other must not be different by more than .002 in. (0.05 mm). The maximum permissible difference between average projection of all cylinder liners under one cylinder head is .004 in. (0.10 mm). The liner projection can change if the liner is turned in the bore. 6. If the liner projection is not .0020 to .0056 in. (0.051 to 0.142 mm), check the thickness of the liner flange (2) and the depth of the liner bore in the cylinder block. The thickness of the liner flange (2) must be .4048 .0008 in. (10.282 0.020 mm).7. The depth of the liner bore in the cylinder block must be .401 .001 in. (10.19 0.03 mm). If the liner bore in the block is worn and the measurement is not correct, the liner bore can be corrected with a cylinder block counterboring tool. See SPECIAL INSTRUCTIONS, FORM FM055228.8. Put a mark on the liner and cylinder block so the liner can be installed in the same position from which it was removed. 9. Install new O-ring seals (4) on the cylinder liners. Put liquid soap on the O-ring seals and in the bases in the cylinder block.
The liners must be installed in the cylinder block immediately after filler band (3) is installed. Make sure the marks on the liners and the cylinder block are in alignment when the cylinder liners are installed.
10. Put (dip) the filler band completely in clean SAE 30 oil and install it on the liner immediately.11. Install the liner in the cylinder block immediately with tooling (C).end by:a) install pistons
1. Clean the cylinder liners and cylinder block. 2. Install the liners (1) in the cylinder block without the O-ring seals and filler bands. See CYLINDER LINER PROJECTION in TESTING AND ADJUSTING. 3. Install tooling (A) and two 5/8" - 11 NC bolts 5 1/2 in. long. Tighten the bolts evenly to 50 lb.ft. (70 N m).4. Check the liner projection with tool (B) at four locations around the liner.5. Liner projection must be .0020 to .0056 in. (0.051 to 0.142 mm). Measurements on the same liner must not be different by more than .002 in. (0.05 mm). Average measurement between liners next to each other must not be different by more than .002 in. (0.05 mm). The maximum permissible difference between average projection of all cylinder liners under one cylinder head is .004 in. (0.10 mm). The liner projection can change if the liner is turned in the bore. 6. If the liner projection is not .0020 to .0056 in. (0.051 to 0.142 mm), check the thickness of the liner flange (2) and the depth of the liner bore in the cylinder block. The thickness of the liner flange (2) must be .4048 .0008 in. (10.282 0.020 mm).7. The depth of the liner bore in the cylinder block must be .401 .001 in. (10.19 0.03 mm). If the liner bore in the block is worn and the measurement is not correct, the liner bore can be corrected with a cylinder block counterboring tool. See SPECIAL INSTRUCTIONS, FORM FM055228.8. Put a mark on the liner and cylinder block so the liner can be installed in the same position from which it was removed. 9. Install new O-ring seals (4) on the cylinder liners. Put liquid soap on the O-ring seals and in the bases in the cylinder block.
The liners must be installed in the cylinder block immediately after filler band (3) is installed. Make sure the marks on the liners and the cylinder block are in alignment when the cylinder liners are installed.
10. Put (dip) the filler band completely in clean SAE 30 oil and install it on the liner immediately.11. Install the liner in the cylinder block immediately with tooling (C).end by:a) install pistons