106873-2831 ZEXEL 9 400 618 391 BOSCH INJECTION-PUMP ASSEMBLY 9400618391 1068732831 me160842


 

Information injection-pump assembly

BOSCH 9 400 618 391 9400618391
ZEXEL 106873-2831 1068732831
MITSUBISHI ME160842 me160842
106873-2831 INJECTION-PUMP ASSEMBLY
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Service parts 106873-2831 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106080-5301
3. GOVERNOR 105489-4051
4. SUPPLY PUMP 105237-5620
5. AUTOM. ADVANCE MECHANIS 105681-1100
6. COUPLING PLATE 105663-0390
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-7411
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 17.7{180}/24.5{250}
13. NOZZLE-HOLDER 105030-4451
14. NOZZLE 105015-9400
15. NOZZLE SET

Include in #1:

106873-2831 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 391 9400618391
ZEXEL 106873-2831 1068732831
MITSUBISHI ME160842 me160842


Zexel num
Bosch num
Firm num
Name
106873-2831 
9 400 618 391 
ME160842  MITSUBISHI
INJECTION-PUMP ASSEMBLY
8M20-I 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   131424-7920
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
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   4.4 4.37 4.43
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cyl.1-2
deg.   45 44.75 45.25
Difference between angles 2
Cal 1-7
deg.   90 89.75 90.25
Difference between angles 3
Cal 1-3
deg.   135 134.75 135.25
Difference between angles 4
Cal 1-4
deg.   180 179.75 180.25
Difference between angles 5
Cal 1-5
deg.   225 224.75 225.25
Difference between angles 6
Cal 1-6
deg.   270 269.75 270.25
Difference between angles 7
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
 
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

Test data 106873-2831
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
----------

Speed control lever angle

Test data 106873-2831
F:Full speed
----------

----------
a=(16deg)+-5deg

0000000901

Test data 106873-2831
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=29.5deg+-3deg

Stop lever angle

Test data 106873-2831
N:Pump normal S:Stop the pump. (1)Drive side stop lever (2)Drive side (3)Rack position = aa (4)Use the hole at R = bb
----------
aa=3.7-0.5mm bb=28mm
----------
a=28.5deg+-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
----------

0000001601 GOVERNOR TORQUE CONTROL

Test data 106873-2831
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=(690)r/min N3=(960)r/min N4=1100r/min RF=R1(10.2)mm Dr1=0.9mm Dr2=0+0.3mm
----------

Timing setting

Test data 106873-2831
(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=12deg
----------
a=(40deg)




Information:

Lubricant Viscosity Chart
Commercial Oils
Failure to follow the commercial oil recommendations can cause shortened engine life due to piston carbon deposits, liner bore polish and/or abnormally higher increasing oil consumption.API CC and CD oils are unacceptable in this Caterpillar diesel engine.
* API specifications CF-4, CF-4/SH or CF-4/SGThe oil specifications above provide guidelines for the selection of commercial products. They may require shortened oil change intervals as determined by close monitoring of oil condition with Scheduled Oil Sampling (S O S). The same viscosity grades are recommended for commercial oils as for CAT oils.Lubricant Total Base Number (TBN)
New engine oil must have a TBN of 20 times (for Precombustion Chamber engines) and 10 times (for direct injection engines) the percent fuel sulfur as measured by ASTM (American Society if Testing Materials) D2896 method. Refer to the Fuel Specifications in this manual for additional information.Caterpillar DI Engines Only
Additional Notes
The percentage of sulfur in the fuel will affect the engine oil recommendations. For fuel sulfur effects, the ASTM D2896 procedure can be used to evaluate the residual neutralization properties of an engine oil. The sulfur products formation depends on the fuel sulfur content, oil formulation, crankcase blowby, engine operating conditions and ambient temperature.The fuel sulfur neutralization of today's new oil formulations along with direct injection (DI) system engines are more effective. Field results indicate that direct injection combustion (DI) systems and the oils now recommended for these engines will operate at an oil TBN equal to 10 times the fuel sulfur above 0.5% and using API CF-4 oils. Caterpillar requirements reflect this value of 10 times for DI engines.Caterpillar still maintains 20 times TBN value for precombustion chamber (PC) engines when using API CD, CE or CF-4 oil when related to fuel sulfur above 0.5%. Used oil analysis should be a part of the overall program to provide the assurance that a particular engine installation with all its parameters (engine, oil, operation, maintenance and fuel) are under control. Engines built prior to 1990 can continue to use DEO-CD single grade viscosity oil or commercial oils provided the engine operates to user satisfaction. Consult with your Caterpillar dealer for the latest lubrication recommendations.Synthetic Base Stock Oils (SPC)
The performance characteristics of the oil depends on the base oil and the additives. The additives in the oil will vary according to the properties of the base oil and the environment in which the oil will perform its function.Synthetic base stock oils are acceptable for use in Caterpillar engines if these oils meet the performance requirements specified for a particular compartment. The performance requirements for engines using synthetic oils is API CF-4 with API CE as an alternative.The use of a synthetic base stock oil does NOT allow extension of the oil drain period simply because of the use of synthetic oil. Any drain period extension must be validated by S O S (oil analysis and test evaluation) to ensure no excessive component wear occurs in a particular application.The synthetic oils have naturally low pour points

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