106873-7810 ZEXEL 9 400 618 516 BOSCH INJECTION-PUMP ASSEMBLY 9400618516 1068737810 me094957

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 516 9400618516

ZEXEL 106873-7810 1068737810

MITSUBISHI ME094957 me094957

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Cross reference number

BOSCH 9 400 618 516 9400618516

ZEXEL 106873-7810 1068737810

MITSUBISHI ME094957 me094957

Zexel num

Bosch num

Firm num

Name

106873-7810

9 400 618 516

ME094957 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9 K 14CD INJECTION PUMP ASSY PE8P PE

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

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

(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.
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L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
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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

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

Stop lever angle

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
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a=41deg+-5deg b=5.5deg+-5deg c=(31deg)

0000001501 RACK SENSOR

(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)
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N1=1100r/min Ra=R1(11.5)+0.9mm
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0000001601 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
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Timing setting

(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:

Start By:a remove rack actuator packageb. remove fuel injection pumps 1. Remove rack (1) from the fuel pump housing. 2. Remove six lifters (2) from the fuel pump housing. Put identification marks on the lifters for installation purposes. 3. Remove camshaft (3) from the fuel pump housing. It may be necessary to use a soft hammer to push the camshaft out of the governor end of the fuel pump housing. 4. Remove races (4) and bearing (5) from the camshaft. Remove ring (6) if necessary. 5. Remove rack bearing (7) from both ends of the housing and dowel (8) if necessary. 6. Use tooling (A), and remove three camshaft bearings (9). 7. Remove the bolts, cover (10) and the gasket. 8. Remove pins (12), the seal and dowels (11) if necessary. Pins (12) must be pushed from the inside out.Assemble Fuel Injection Pump Housing
1. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged. 2. Lubricate the seal with clean engine oil, and install pin (12). Pin (12) must protrude into the pump bore 2.15 .05 mm (0.85 .002 in.).3. Install dowel (11) so that it protrudes into the pump bore 1.93 .05 mm (0.76 .002 in.). 4. Install the gasket, cover (10) and the bolts. 5. Install the rack bearing with tooling (B). Install the bearing until the driver comes in contact with the plate. The bearing should be installed to a depth of 83.0 0.5 mm (3.27 .02 in.) from the fuel pump mounting face. 6. Measure the rack bearing (7). Dimension (X) must be 11.178 0.05 mm (.4400 .002 in.). Dimension (W) must be 12.767 0.058 mm (.5026 .0022 in.). 7. Install dowel (8). Dowel (8) must protrude 6.0 0.5 mm (.24 .02 in.) from the fuel pump housing face.8. Install the rear rack bearing with tooling (C) to a depth of 7.16 0.13 mm (.282 .005 in.) below the fuel pump housing surface. The inside diameter of the rear rack bearing must be 12.746 0.045 mm (.5018 .0017 in.). 9. User tooling (D), and install three camshaft bearings (9). Oil holes (13) in the camshaft bearings must be positioned 30° 3° above the horizontal centerline toward the engine side of the fuel pump housing. The outer bearings must be installed 1.0 0.5 mm (0.04 0.02 in.) below the surface marked (Z). The inner bearing must be installed 218.0 0.3 mm (8.58 .012 in.) below the front surface (Y). Diameter (XX) must be 68.339 0.038 mm (2.6905 0.015 in.) after assembly. 10. Install ring (6) races (4) and bearing (5) on the camshaft. 11. Lubricate can bearings (9) and cam shaft bearing journals with clean engine oil.12. Install camshaft (3) into the fuel pump housing.
The notch on the lifter must be in line with the dowel in the lifter bore. The lifter must slide up and