106873-7402 ZEXEL 9 400 618 489 BOSCH INJECTION-PUMP ASSEMBLY 9400618489 1068737402 me094459


 

Information injection-pump assembly

BOSCH 9 400 618 489 9400618489
ZEXEL 106873-7402 1068737402
MITSUBISHI ME094459 me094459
106873-7402 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 400 618 489 9400618489
ZEXEL 106873-7402 1068737402
MITSUBISHI ME094459 me094459


Zexel num
Bosch num
Firm num
Name
106873-7402 
9 400 618 489 
ME094459  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.   115.5 112 119
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.   14 11.9 16.1
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.   115.5 114.5 116.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.2
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   123 119 127
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   (R1-0.55 )
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   113.5 109.5 117.5
Fixing the lever   *
Timer adjustment
Pump speed r/min   880--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   830
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1050
Advance angle deg.   3 2.5 3.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 106873-7402
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=AC91
----------

Speed control lever angle

Test data 106873-7402
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=35.5deg+-3deg

Stop lever angle

Test data 106873-7402
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 (equivalent to R = dd).
----------
aa=54mm bb=1100r/min cc=3+-0.3mm dd=17.5mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)

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=335r/min Ra=7.9+-0.1mm
----------

Timing setting

Test data 106873-7402
(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:

Air Shutoff Solenoid (If Equipped)
This optional solenoid is located on top of the engine in the air inlet system. When the solenoid is activated, the solenoid mechanically shuts off inlet air to the engine. The solenoid can only be activated by the overspeed switch or the emergency stop switch.Fuel Shutoff Solenoid
This solenoid is located on the governor or on the fuel injection pump. When the solenoid is activated, the solenoid moves the fuel rack (either directly or through the governor) to the Fuel Off position.Overspeed Shutoffs
Magnetic pickup (1), mounted in the flywheel housing (2).A magnetic pickup mounted in the flywheel housing senses the passage of the flywheel ring gear teeth. Should the engine speed increase above the overspeed setting of the Electronic Speed Switch (118 percent of rated engine speed), the magnetic pickup will sense the overspeed. The overspeed condition activates both the air (if equipped) and fuel shutoff solenoids.The shutoffs must be reset before the engine will restart. A reset button on the Electronic Speed Switch (in the junction box) must be pushed to open the overspeed switch. The air shutoff lever (at the top of the air inlet housing) must be manually reset.If equipped with a Caterpillar Generator Set Control Panel, the devices on the panel must be reset after an overspeed shutoff. Turn the Engine Control Switch to the OFF/RESET position.Oil Pressure Switches
Typical example of oil pressure switches, mounted in the rear of the junction box.An oil pressure switch has wires connected to the electrical system for alarm or shutoff functions. The oil pressure switch senses oil pressure at the bearing oil gallery. If sufficient oil pressure is not achieved after engine starting, or if the engine has been running normally and then loses oil pressure, the fuel shutoff solenoid is energized to shut the engine off. No resetting procedure is required.Engine Step Oil Pressure
This is an adjustable engine speed setting that protects the engine from a failure caused by too little oil pressure for a specified speed range. This option requires two different oil pressure switches. One switch has a high pressure rating- when the engine is running above the speed setting, the engine must maintain oil pressure higher than the switch rating. The other switch has a low pressure rating- an engine running below the speed setting must maintain oil pressure above the low switch rating.In an automatic start/stop system, an automatic reset switch is used. Manually operated systems require the switch to be reset before the engine will start.
If the RESET button does not move to the extended position after the engine starts, the engine will NOT be protected by this particular switch.If the RESET button remains in the reset position, the engine oil pump will not develop normal oil pressure. An inspection should be made to correct the problem.
In order to reset the switch, push the RESET button until the button latches. After the engine starts and develops oil pressure, the button will move to the extended (running) position.
The button must

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