Information injection-pump assembly
BOSCH
9 400 618 378
9400618378
ZEXEL
106873-2702
1068732702
MITSUBISHI
ME160607
me160607
Rating:
Service parts 106873-2702 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/24.5{250}
15.
NOZZLE SET
Include in #1:
106873-2702
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 618 378
9400618378
ZEXEL
106873-2702
1068732702
MITSUBISHI
ME160607
me160607
Zexel num
Bosch num
Firm num
Name
106873-2702
9 400 618 378
ME160607 MITSUBISHI
INJECTION-PUMP ASSEMBLY
8M20-I K
8M20-I K
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
131424-7920
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
4.4
4.37
4.43
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.75 45.25
Cyl.1-2 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25
Cal 1-3 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25
Cal 1-6 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-8 deg. 315 314.75 315.25
Cal 1-8 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
-
Rack position
10.2
Pump speed
r/min
650
650
650
Each cylinder's injection qty
mm3/st.
147.5
143.1
151.9
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
18
15.3
20.7
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.2)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
147.5
146.5
148.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.9
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
164.5
160.5
168.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
180
160
200
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Excess fuel setting for starting: SXL
(3)Damper spring setting
----------
SXL=11.3+-0.1mm
----------
----------
SXL=11.3+-0.1mm
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
----------
----------
a=19.5deg+-5deg
----------
----------
a=19.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=21.5deg+-3deg
----------
----------
a=10deg+-5deg b=21.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Drive side
(2)Use the hole at R = aa
(3)Rack position bb
(4)Stopper bolt setting
----------
aa=36mm bb=3.7-0.5mm
----------
a=10.5deg+-5deg b=57deg+7deg-5deg
----------
aa=36mm bb=3.7-0.5mm
----------
a=10.5deg+-5deg b=57deg+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=5.9+-0.1mm
----------
----------
N1=325r/min Ra=5.9+-0.1mm
----------
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.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
0000001701 GOVERNOR TORQUE CONTROL
Dr:Torque control stroke
(A): Without torque control spring capsule
1. Adjustment procedures
(1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting.
2. Procedures for adjustment
(1)Remove the torque control spring capsule.
(2)Operate the pump at approximately N1. (End of idling spring operation < N1.)
(3)Tilt the lever to the full side.
(4)Set so that R = RF.
(5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window.
(6)Adjust so that the torque control stroke Dr1 can be obtained.
(7)Align N2 and N3 with the torque control spring capsule.
3. Final confirmation
(1)After final confirmation, temporarily set the load lever to N = N1, R = idling position.
(2)From this condition, increase speed to N = N4.
(3)Confirm that positive torque control stroke is Dr2.
----------
N1=500r/min N2=(700)r/min N3=(940)r/min N4=1100r/min RF=R1(10.2)mm Dr1=0.9mm Dr2=0+0.3mm
----------
----------
N1=500r/min N2=(700)r/min N3=(940)r/min N4=1100r/min RF=R1(10.2)mm Dr1=0.9mm Dr2=0+0.3mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=10deg
----------
a=(40deg)
----------
aa=10deg
----------
a=(40deg)
Information:
Storage Procedure
When a generator is in storage for any length of time, moisture condenses in the windings. Minimize the condensation by use of a dry storage space and space heaters. Refer to step 2 belowIf a brush-type generator (SRCR) is to be in storage for a year or more, lift the brushes off the slip ring to prevent damage to the slip ring by chemical action.After Storage
Test the main stator windings with a megohmmeter in the following situations: 1. Before initial startup of generator set.2. Every 3 months* if generator is operating in a humid environment.3. If generator has not been run under load for 3 months* or more.*This is a guideline only. It may be necessary to megger more frequently if environment is extremely humid, salty or if the last megger test was close to 1 megohm.The megohmmeter test is described in Service Manuals SENR2180 or SENR7968. A reading of 1 meghom or less indicates that the winding has absorbed too much moisture.To Remove Moisture
To remove moisture caused by high humidity, use one of the following methods to make the generator dry:1. Energize space heaters in generator if so equipped.2. Put the generator in an oven at a temperature of not more than 85°C (185°F) for four hours.
If an oven is used for drying, use a forced air type rather than a radiant type. Radiant ovens can cause localized overheating.
3. Space heaters of the same type used in marine applications, can be installed on generators. (See the Parts Book.) These heaters heat the windings to remove moisture and should be connected at all times in high humidity conditions whenever the generator is not running.4. Use a canvas enclosure around the generator and heating lamps to increase the temperature. Make an opening in the top for release of moisture.5. Send a low voltage current through the windings to increase the temperature of the windings. Do not exceed 85°C (185°F).If the megohmmeter test reads under 1 megohm after the drying or if it goes below 1 megohm shortly after drying, contact your Caterpillar dealer. The insulation has deteriorated and should be reconditioned.
When a generator is in storage for any length of time, moisture condenses in the windings. Minimize the condensation by use of a dry storage space and space heaters. Refer to step 2 belowIf a brush-type generator (SRCR) is to be in storage for a year or more, lift the brushes off the slip ring to prevent damage to the slip ring by chemical action.After Storage
Test the main stator windings with a megohmmeter in the following situations: 1. Before initial startup of generator set.2. Every 3 months* if generator is operating in a humid environment.3. If generator has not been run under load for 3 months* or more.*This is a guideline only. It may be necessary to megger more frequently if environment is extremely humid, salty or if the last megger test was close to 1 megohm.The megohmmeter test is described in Service Manuals SENR2180 or SENR7968. A reading of 1 meghom or less indicates that the winding has absorbed too much moisture.To Remove Moisture
To remove moisture caused by high humidity, use one of the following methods to make the generator dry:1. Energize space heaters in generator if so equipped.2. Put the generator in an oven at a temperature of not more than 85°C (185°F) for four hours.
If an oven is used for drying, use a forced air type rather than a radiant type. Radiant ovens can cause localized overheating.
3. Space heaters of the same type used in marine applications, can be installed on generators. (See the Parts Book.) These heaters heat the windings to remove moisture and should be connected at all times in high humidity conditions whenever the generator is not running.4. Use a canvas enclosure around the generator and heating lamps to increase the temperature. Make an opening in the top for release of moisture.5. Send a low voltage current through the windings to increase the temperature of the windings. Do not exceed 85°C (185°F).If the megohmmeter test reads under 1 megohm after the drying or if it goes below 1 megohm shortly after drying, contact your Caterpillar dealer. The insulation has deteriorated and should be reconditioned.
Have questions with 106873-2702?
Group cross 106873-2702 ZEXEL
Mitsubishi
106873-2702
9 400 618 378
ME160607
INJECTION-PUMP ASSEMBLY
8M20-I
8M20-I