106873-7300 ZEXEL 9 400 611 037 BOSCH INJECTION-PUMP ASSEMBLY 9400611037 1068737300 me094239


 

Information injection-pump assembly

BOSCH 9 400 611 037 9400611037
ZEXEL 106873-7300 1068737300
MITSUBISHI ME094239 me094239
106873-7300 INJECTION-PUMP ASSEMBLY
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Service parts 106873-7300 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106080-5810
3. GOVERNOR 105923-1620
4. SUPPLY PUMP 105237-4770
5. AUTOM. ADVANCE MECHANIS 105691-3910
6. COUPLING PLATE 105664-2020
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-7450
11. Nozzle and Holder ME093733
12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}
13. NOZZLE-HOLDER 105041-4120
14. NOZZLE
15. NOZZLE SET 105019-0620

Include in #1:

106873-7300 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 037 9400611037
ZEXEL 106873-7300 1068737300
MITSUBISHI ME094239 me094239


Zexel num
Bosch num
Firm num
Name
106873-7300 
106873-7430 
9 400 611 037 
ME094239  MITSUBISHI
INJECTION-PUMP ASSEMBLY
8DC9 K

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8250
Bosch type code   1 688 901 101
Nozzle   105780-0120
Bosch type code   1 688 901 990
Nozzle holder   105780-2190
Opening pressure MPa   20.7
Opening pressure kgf/cm2   211
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   8-3-600
Overflow valve   131425-0220
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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
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   3.9 3.85 3.95
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   11.5
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   115 111.5 118.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   8+-0.5
Pump speed r/min   430 430 430
Each cylinder's injection qty mm3/st.   19 16.1 21.9
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.5)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   115 114 116
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.   117 113 121
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.6
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   111 107 115
Fixing the lever   *

Test data Ex:

Governor adjustment

Test data 106873-7300
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Damper spring setting
----------
T1=AC73
----------

Timer adjustment

Test data 106873-7300
(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=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

Test data 106873-7300
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=32deg+-5deg b=39deg+-3deg

Stop lever angle

Test data 106873-7300
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.) (3)Normal engine position (Rack position corresponding to dd)
----------
aa=54mm bb=1100r/min cc=3+-0.3mm dd=17.5mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)

0000001501 RACK SENSOR

Test data 106873-7300
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1100r/min Ra=R1(11.5)+0.9mm
----------

Timing setting

Test data 106873-7300
(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=4deg
----------
a=(50deg)




Information:

You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.Before proceeding with this maintenance interval, perform previous maintenance interval requirements. Perform the maintenance at the interval listed in the Maintenance Schedule for your engine.Engine Protection Controls
Inspect For Proper Operation
The engine protective alarm and shutoff controls must be tested, inspected and checked by an authorized Caterpillar dealer at least every year or 1000 hours for proper operation. The manual shutoff functions should be tested to ensure proper operation and protection to the engine. Refer to Engine Control, Monitoring and Protection in the Operation Section in this Manual. Have the checks made by a qualified mechanic. Consult your authorized Caterpillar engine dealer, or refer to the Service Manual for your engine. Check Alarm and Shutdown Settings
Check for loose, broken, or damaged wiring or components. Check the condition of all sensors and wiring. Repair or replace any broken or malfunctioning sensors before they become a problem. The inspection only takes a few minutes and could avert a potential problem that could cause your engine to fail. Check GSC Display Window Readings
Refer to the operating parameters in the Engine Control, Monitoring and Protection topic.While operating, observe all GSC display window readings hourly, especially the engine oil pressure, fuel pressure and coolant temperature.Operational Checks
Start the engine. Use the starting procedure found in the Engine Starting topic in this publication.The operational checks are intended to check the engine starting and stopping, lubrication and fuel systems as well as overall operation. The checks should take no longer than five minutes to complete. Longer periods of operation are not required. A more thorough Performance Analysis should be performed with the engine operating under load.Automatic Switches
Check that all switches are in proper position for automatic start. The shutoff controls must be checked so that they function properly when they are required. To prevent damage to the engine while performing the test, only authorized personnel or your Caterpillar dealer should perform the checks.SR4 Generator
Make sure residual voltage in the rotor, stator and the generator is discharged.If this generator is to be connected to a utility electrical distribution system, it must be isolated from the distribution system by means of:a. Opening the main switch in the case of the generator temporarily connected to the system or,b. A double throw (transfer) switch in the case of a permanent connection to the system.Failure to do so could result in personal injury or death due to electrical shock. This warning does not apply when a generator and utility distribution system are designed and approved by the utility to run in parallel.
Before working inside the generator, make sure that the starting motor can not be activated by any automatic or manual signal.Electronic components in the regulator can be damaged during generator operation if contact is made between the part and ground.
Check Winding Insulation Resistance
When the engine-generator is operating, voltages up to 600V are present in these areas near

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