106873-7442 ZEXEL 9 400 618 491 BOSCH INJECTION-PUMP ASSEMBLY 9400618491 1068737442 me094490


 

Information injection-pump assembly

BOSCH 9 400 618 491 9400618491
ZEXEL 106873-7442 1068737442
MITSUBISHI ME094490 me094490
106873-7442 INJECTION-PUMP ASSEMBLY
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Cross reference number

BOSCH 9 400 618 491 9400618491
ZEXEL 106873-7442 1068737442
MITSUBISHI ME094490 me094490


Zexel num
Bosch num
Firm num
Name
106873-7442 
9 400 618 491 
ME094490  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 106873-7442
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 106873-7442
(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=(10deg) 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 106873-7442
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 106873-7442
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 106873-7442
(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
----------

0000001601 SPEED SENSOR

Test data 106873-7442
(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------

Timing setting

Test data 106873-7442
(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:

Heavy Duty Air Cleaners
Generator set engines equipped with heavy duty air cleaners have a serviceable air cleaner element. The element may be cleaned up to six times, but must be replaced Every Year.Remove and Install Air Cleaner Elements
Heavy duty air cleaner:(1) service indicator(2) upper body (air filter element housing)(3) clamps(4) lower body (tube element)(5) dust collector cup1. Loosen clamps (3) between the lower body (4) and the dust collector cup (5). Remove the cup.2. Loosen the clamps between the lower body and the upper body (2). Remove the tube element.3. Clean the tubes from both sides with water or air.4. Remove the air filter element from the upper body (2). Wipe the inside of the upper body clean.5. Inspect and clean air filter element. Install a clean or new element.6. Inspect the gasket between the upper body and lower body. Inspect the seal between the lower body and the dust collector cup. Install a new gasket and seal if necessary.7. Install the cleaned, dry tube element. Tighten the retaining clamps attaching the lower body to the upper body.8. Wipe the dust collector cup clean. Install the cup and tighten the retaining clamps.9. Reset the service indicator (1).Cleaning Air Filter Elements
The primary element (Caterpillar air filters) can be cleaned several times before replacement. The element, when cleaned, should be thoroughly checked for rips or tears in the filter material.Replace the primary element at least EVERY YEAR regardless of operating hours it has accumulated.
Do not clean filter elements by bumping or tapping.Do not use filter elements with damaged pleats, gaskets or seals. Engine damage could result.
Filter elements can be cleaned with air pressure, 205 kPa (30 psi) maximum, or water pressure, 280 kPa (40 psi) maximum, or detergent washing. Have spare elements on hand to use while cleaning used elements.* Direct air or water along the length of the plate inside and outside of air filter element.The element can be washed in warm water and nonsudsing household detergent, such as automatic dishwasher detergent. Rinse inside and outside the pleats. The filter should then be thoroughly air dried and inspected.* Inspect the filter elements after cleaning for any rips, tears or damage. Insert a light inside of the clean, dry element. Do not use a filter element with damaged pleats, gaskets or seals. Discard the element if damaged.* Wrap and store the clean filter elements in a clean, dry place.* Reset the service indicator by pushing the piston plunger in.For more information on air cleaner element cleaning, refer to Guideline for Reusable Parts-Cleaning and Inspection of Air Filters, SEBU8062.Air Starter & Air Tank (If Equipped)
Check Lubricator Level
Never allow the lubricator bowl (if equipped) to become empty. The starting motor will be damaged by lack of proper lubrication.
The vanes of the starting motor are lubricated with a fine mist of oil from the motor lubricator. Check the level of oil in the lubricator bowl. If the bowl is less than half full, add lubricant. Use non detergent 10W engine oil for temperatures

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