106873-2750 ZEXEL 9 400 618 383 BOSCH INJECTION-PUMP ASSEMBLY 9400618383 1068732750 me092503

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 383 9400618383

ZEXEL 106873-2750 1068732750

MITSUBISHI ME092503 me092503

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Service parts 106873-2750 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7720

3. GOVERNOR 105487-5870

4. SUPPLY PUMP 105207-1140

5. AUTOM. ADVANCE MECHANIS 105636-1670

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:

106873-2750 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 383 9400618383

ZEXEL 106873-2750 1068732750

MITSUBISHI ME092503 me092503

Zexel num

Bosch num

Firm num

Name

106873-2750

9 400 618 383

ME092503 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC92 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 134424-1320

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 9.3

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 112.5 109.1 115.9

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(9.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 112.5 111.5 113.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.3)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 118.5 113.3 123.7

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. 150 110 190

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
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

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=10.2+-0.1mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=19.5deg+-5deg

0000000901

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

----------
a=10deg+-5deg b=23deg+-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 delivery)
----------
aa=4-0.5mm bb=11.7mm
----------
a=45.5deg+7deg-5deg b=22deg+-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=325r/min Ra=5.6+-0.1mm
----------

0000001601 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=R1(9.3)mm Rb=R1-0.4mm P1=(97.3)kPa((730)mmHg) P2=84.6+-0.7kPa(635+-5mmHg) Q1=(112.5)+-1cm3/1000st Q2=(103.1)+-3cm3/1000st

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:

Table 1
Revision Summary of Changes
02 Added serial number prefixes Description Of Change: An updated Diesel Exhaust Fluid (DEF) control unit software is now used on the machine engines listed above. The updated software has been released to improve the priming performance of the DEF pumps in cold environments.Adaptable To:
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.The new and former part numbers are listed in Table 2.
Table 2
Required Parts
Qty Dosing Control Unit (DCU) Dosing Control Unit (DCU) Voltage New Part Number Part Name Former Part Number(1)
1 Restriction on Hazardous Substance (RoHS) (DCU) 24V 593-7031 Engine Software 567-5763
1 Restriction on Hazardous Substance (RoHS) (DCU) 12V 593-7030 Engine Software 567-5761
1 Non-Restriction on Hazardous Substance (RoHS) (DCU) 24V 593-7033 Engine Software 539-3577
1 Non-Restriction on Hazardous Substance (RoHS) (DCU) 12V 593-7032 Engine Software 539-3576
(1) The former part number listed is for reference only and may differ.The new software is available in the form of a flash file through the Cat ® Service Information System (SIS). A newer part number may be available. SIS Web only displays the latest available flash file.