106873-2820 ZEXEL 9 400 618 390 BOSCH INJECTION-PUMP ASSEMBLY 9400618390 1068732820 me092805


 

Information injection-pump assembly

BOSCH 9 400 618 390 9400618390
ZEXEL 106873-2820 1068732820
MITSUBISHI ME092805 me092805
106873-2820 INJECTION-PUMP ASSEMBLY
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Service parts 106873-2820 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106087-7870
3. GOVERNOR 105487-6210
4. SUPPLY PUMP 105237-1321
5. AUTOM. ADVANCE MECHANIS 105681-1000
6. COUPLING PLATE 105663-0390
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-7011
11. Nozzle and Holder ME091308
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:

106873-2820 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 390 9400618390
ZEXEL 106873-2820 1068732820
MITSUBISHI ME092805 me092805


Zexel num
Bosch num
Firm num
Name
106873-2820 
9 400 618 390 
ME092805  MITSUBISHI
INJECTION-PUMP ASSEMBLY
8DC91T2 * 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   11.7+-0. 5
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   156 151.3 160.7
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(11.7)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   156 155 157
Basic   *
Fixing the lever   *
Boost pressure kPa   33.3 33.3
Boost pressure mmHg   250 250
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(11.7)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   165 158 172
Difference in delivery mm3/st.   14 14 14
Fixing the lever   *
Boost pressure kPa   33.3 33.3
Boost pressure mmHg   250 250
Injection quantity adjustment_05
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   120 80 160
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Boost compensator adjustment
Pump speed r/min   650 650 650
Rack position   R2(R1-1. 5)
Boost pressure kPa   8 8 8
Boost pressure mmHg   60 60 60
Boost compensator adjustment_02
Pump speed r/min   650 650 650
Rack position   R1-0.6
Boost pressure kPa   12 10.7 13.3
Boost pressure mmHg   90 80 100
Boost compensator adjustment_03
Pump speed r/min   650 650 650
Rack position   R1(11.7)
Boost pressure kPa   20 13.3 26.7
Boost pressure mmHg   150 100 200
Timer adjustment
Pump speed r/min   -
Advance angle deg.   0 0 0
Remarks
Measure speed (beginning of operation).
 
Timer adjustment_02
Pump speed r/min   1000
Remarks
Measure the actual advance angle.
 
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   4 4 4
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 106873-2820
N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Boost compensator cancel stroke: BSL (3)Boost compensator stroke: BCL (4)Damper spring setting
----------
BSL=1.6mm BCL=1.5+-0.1mm
----------

Speed control lever angle

Test data 106873-2820
F:Full speed
----------

----------
a=(11.5deg)+-5deg

0000000901

Test data 106873-2820
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=(33deg)+-3deg

Stop lever angle

Test data 106873-2820
S:Stop the pump. (1)Rack position = aa (2)Free (at delivery) (3)Stopper bolt setting
----------
aa=3.3-0.5mm
----------
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
----------
N1=325r/min Ra=5.6+-0.1mm
----------

Timing setting

Test data 106873-2820
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)




Information:

Most commercial antifreezes are formulated for gasoline engine applications and will, therefore, have high silicate content. ASTM D4985 antifreeze is a low silicate antifreeze and should be used if not using Caterpillar Antifreeze. The percentage of antifreeze and water should be determined by the amount of freeze protection required. Follow the instructions provided by the antifreeze supplier.When using any antifreeze (except Caterpillar Antifreeze) supplemental coolant additive is required at initial fill. Caterpillar or other manufacturer's products can be used as the supplemental coolant additive.Add 1 liter (1 U.S. quart) of liquid supplemental coolant additive for every 15 liter (4 U.S. gallon) so that the cooling system will have a three to six percent concentration of supplemental coolant additive.DO NOT mix Caterpillar Supplemental Coolant Additive (Conditioner) or supplemental coolant additive elements with the other products available; select a cooling system treatment and use it exclusively. If other than Caterpillar products are used as the supplemental coolant additive, follow the manufacturers' recommendation for cooling system treatment and test evaluation.Supplemental Coolant Additive (Conditioner or Inhibitor)
Never use coolant in Caterpillar engines without supplemental coolant additive regardless of antifreeze concentration.Caterpillar or other manufacturer's products can be used as the supplemental coolant additive. DO NOT mix Caterpillar Supplemental Coolant Additive (Conditioner) liquid or elements with the other commercial products available; select a cooling system treatment and use it exclusively.Excessive concentration of supplemental coolant additive can form deposits which may cause engine damage, reduce the engine's heat transfer characteristics and could also accelerate water pump seal wear.
The cooling system MUST contain supplemental coolant additives (conditioner or inhibitor) to control corrosion, cavitation and deposits. It is also necessary to prevent rust, scale, pitting and/or corrosion of engine parts contacted by coolant. The cooling system should be protected with a minimum of three percent concentration at all times, regardless of the concentration of antifreeze. Use supplemental coolant additive liquid OR an element (if equipped) to maintain a three to six percent concentration in the cooling system.Use the 8T5296 Test Kit to check and monitor the SCA concentration for antifreeze/water coolant mixture. The Caterpillar 8T5296 Test Kit checks for concentration of nitrates in the coolant solution. Some other manufacturers' supplemental coolant additive (SCA) are phosphate based and the 8T5296 Test Kit will NOT provide accurate results. Caterpillar recommends that their test kit be used to check coolant solution concentration.If other than Caterpillar products are used as the supplemental coolant additive, follow the manufacturers' recommendation for cooling system treatment and test evaluation. Commercial supplemental coolant additive products must contain silicates and a minimum of 70 gr/U.S. gallon (1200 ppm) nitrites.Caterpillar liquid supplemental coolant additive (Conditioner) is available through your Caterpillar dealer in quantities that follow. Pre-chargeCaterpillar Antifreeze DOES NOT require supplemental coolant additive added at initial fill, however additive is required on a maintenance basis. For engines equipped with supplemental coolant additive elements, the last MAINTENANCE element should not be replaced at FLUSH & FILL or Overhaul until the next oil change interval. Corrosion in raw (sea) water

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