106873-2411 ZEXEL 9 400 618 357 BOSCH INJECTION-PUMP ASSEMBLY 9400618357 1068732411 me092083

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 357 9400618357

ZEXEL 106873-2411 1068732411

MITSUBISHI ME092083 me092083

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Service parts 106873-2411 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7890

3. GOVERNOR 105487-5591

4. SUPPLY PUMP 105237-5580

5. AUTOM. ADVANCE MECHANIS 105681-1020

6. COUPLING PLATE 105663-0390

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7011

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105030-4980

14. NOZZLE 105015-8500

15. NOZZLE SET

Include in #1:

106873-2411 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 357 9400618357

ZEXEL 106873-2411 1068732411

MITSUBISHI ME092083 me092083

Zexel num

Bosch num

Firm num

Name

106873-2411

9 400 618 357

ME092083 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9T7 K

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 255 221 289

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

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 10.8

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 134.6 130.6 138.6

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. 15.8 13.4 18.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.8)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 134.6 133.6 135.6

Basic *

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.8)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 142.4 138.4 146.4

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Injection quantity adjustment_05

Adjusting point D

Rack position -

Pump speed r/min 200 200 200

Average injection quantity mm3/st. 97 57 137

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point E

Rack position R1+0.35

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 142.8 139.8 145.8

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Injection quantity adjustment_07

Adjusting point F

Rack position R1-0.9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 116.8 114.8 118.8

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_08

Adjusting point G

Rack position 12.2+-0. 1

Pump speed r/min 200 200 200

Average injection quantity mm3/st. 142 132 152

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Rack limit *

Boost compensator adjustment

Pump speed r/min 450 450 450

Rack position R1-0.9

Boost pressure kPa 3.3 3.3 5.3

Boost pressure mmHg 25 25 40

Boost compensator adjustment_02

Pump speed r/min 450 450 450

Rack position R1(10.8)

Boost pressure kPa 10 8.7 11.3

Boost pressure mmHg 75 65 85

Boost compensator adjustment_03

Pump speed r/min 450 450 450

Rack position (11.7)

Boost pressure kPa 15.3 15.3 15.3

Boost pressure mmHg 115 115 115

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Adjust with the load control lever in the full position (variable speed specification). (3)Tolerance for racks not indicated: +-0.05mm. (4)Boost compensator cancel stroke: BSL (5)RACK LIMIT: RAL (6)Boost compensator stroke (7)Damper spring setting (8)When air cylinder is operating.
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BSL=1.4mm RAL=12.2+-0.1mm
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Speed control lever angle

I:Idle (1)Set the pump speed at aa (2)Set the pump speed at bb. (3)Set the pump speed to cc.
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aa=1275r/min bb=1190r/min cc=275r/min
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a=(6.5deg)+-5deg b=(16.5deg)+-5deg c=(2deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=30.5deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa, speed = bb (non-injection rack position) (2)Stopper bolt setting (3)Free (at delivery)
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aa=3.3-0.5mm bb=1275r/min
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a=10.5deg+-5deg b=58deg+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
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N1=325r/min Ra=5.8+-0.1mm
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0000001601 2-STAGE CHANGEOVER DEVICE

RFD governor 2 stage changeover mechanism adjustment outline (A) Bolt (B) bolt (c) Nut (D) Return spring (E) Bolt (F) Bolt (G) Screw (H) Bolt (I) Load lever (J) Speed lever (K) Air cylinder (M Air inlet Figure 1 is only for reference. Lever shape, etc, may vary. 1. Minimum-maximum speed specification adjustment (when running) (a) Without applying air to the air cylinder, loosen bolts (A) and (B). (1)High speed return L setting (a) In the speed range Nf~Nf - 300r/min, adjust using the speed adjusting bolt to determine the temporary beginning of high speed control speed. (b) Determine the rack position in the vicinity of Rf using the full load lever. (c) Increase speed and confirm return distance L. (d) Adjust using the tension lever bolt to obtain L. (2)Setting full load rack position Rf (a) Move the load control lever to the full side. (b) Adjust the full load adjusting bolt so that Rf can be obtained, then fix. (3)Setting the beginning of high speed operation Nf (a) Adjust using bolt (E) so that Nf can be obtained, and then fix. (4)Idle control setting (Re, Ni, Rc) (a) Set the speed at Ns + 200r/min and move the load control lever to the idle side. (b) Fix the lever in the position where Re can be obtained. (c) Next, decrease speed to Ni and screw in the idle spring. (d) Adjust to obtain rack position Ri. (e) Increase the speed and after confirming that the rack position is Re at Ns, set the speed at 0. (f) Confirm protrusion position Rc at idle. (5)Damper spring adjustment (a) Increase speed and set the speed at the rack position Rd - 0.1 mm (b) Set using the damper spring so that the rack position Rd can be obtained. (c) When Rd is not specified, Rd = Ri - 0.5 mm. (6)High speed droop confirmation (a) Return the load control lever to the full load lever position. (b) Increase the speed and confirm that Rf can be obtained at Nf r/min. (c) Confirm that speed is Nh at rack position Rh. 2. Variable speed specification adjustment (at operation) (a) Remove return spring (D). (b) Apply air pressure of 245~294 kPa {2.5~3 kg/cm2} to the air cylinder. (c) Perform the following adjustment in this condition. (1)Setting full load rack position Rf' (a) Pull the load lever to the idle side. (b) Obtain rack position Rf' using the nut (C). (Pump speed is Nf'-50 r/min.) (2)Setting full speed Nf' (a) Adjust using bolt (B) so that Nf can be obtained, and then fix. (3)Low speed side setting (a) At 350r/min, set bolt (F) at beginning of governor operation position, then fix. 3. Bolt (A) adjustment (1)Install return spring (D) and perform the adjustments below at air pressure 0. (a) Set at speed Nf using bolt (E). (b) Screw in bolt (A). (c) Screw in 1 more turn from the speed lever contact position (d) Fix bolt (A). (e) At this time confirm that the air cylinder's shaft moves approximately 1 mm towards the governor. 4. Lever operation confirmation using the air cylinder (1)Apply 588 kPa {6 kg/cm2} air pressure to the air cylinder. (2)Confirm that the cylinder piston is moved 50 mm by the spring (D).
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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)-
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a=(40deg)

Information:

Possible Causes/Corrections
Air Or Water In Fuel System
With air in the fuel system, the engine will normally be difficult to start, run rough, and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut at the through the head adapter and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the through the head adapters until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air cannot be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leaks at the connection between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. If there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside furl supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.Water in the fuel can cause rough running and possible fuel system damage.Valve Adjustment Not Correct
Check and make necessary adjustments as in Testing And Adjusting Section of the Service Manual. Intake valve lash is 0.38 mm (.015 in) and exhaust valve lash is 0.64 mm (.025 in). Also check for a bent or broken push rod.Defective Fuel Nozzle(s)
Find a defective nozzle by running engine at the rpm where it runs rough. Loosen the fuel line nut at the through the head adapter enough to stop fuel supply to that cylinder. Each cylinder must be checked this way. If a cylinder is found where loosening of the nut makes no difference in the rough running, test the nozzle for that cylinder. To test a nozzle, remove the nozzle from the engine and test as in Testing and Adjusting Section of this Service Manual.Fuel Leakage From Fuel Injection Line Nut
Tighten nut to 40 7 N m (30 5 lb ft). Again check for leakage. Be sure to check fuel injection lines inside valve cover base.Defective Fuel Injection Pump
An injection pump can have a good fuel flow coming from it but cause rough running because of slow timing that is caused by wear on the bottom end of the plunger. See the Testing and Adjusting Section in this Service Manual for the correct specifications and procedure to check plungers and lifters.Fuel pumps which are severely scored from debris can cause rough running but fuel dilution usually occurs before horsepower is affected.Low installation torque on the fuel pump retaining nut can cause misfire, rough running and low power.Fuel Has A High "Cloud Point"
In cold weather operation this condition should be checked first. The fuel "cloud point"