106873-7831 ZEXEL 9 400 618 518 BOSCH INJECTION-PUMP ASSEMBLY 9400618518 1068737831 me094959

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 518 9400618518

ZEXEL 106873-7831 1068737831

MITSUBISHI ME094959 me094959

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Cross reference number

BOSCH 9 400 618 518 9400618518

ZEXEL 106873-7831 1068737831

MITSUBISHI ME094959 me094959

Zexel num

Bosch num

Firm num

Name

106873-7831

9 400 618 518

ME094959 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

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=AC74
----------

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.
----------
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

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting (3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=32deg+-5deg b=(42deg)+-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 (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
----------

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

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 timing gear coverb. remove fuel injection pump housing and rack actuator package 1. Remove four bolts (2) plate (3) and idler gear (1). 2. If the camshaft is not going to be removed, use tooling (A) to remove camshaft gear (4).
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves, or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.4. Remove timing gear plate (6). 5. Use tooling (B) to remove the bearing from the idler gear. The following steps are for the installation of the timing gears and plate.6. Install a new gasket in the timing gear plate.7. Put timing gear plate (6) in position on the cylinder block, and install the bolts that hold the timing gear plate to the cylinder block.8. Heat camshaft gear (4) to a maximum temperature of 315° C (600° F), and install it on the camshaft.9. Use tooling (B), and install the bearing in the idler gear. Set the gear to the front face, (face with timing marks). Drive the bearing from the rear face toward the front face of the gear. Install the bearing to a depth of 1.5 0.5 mm (.06 .02 in.) below the rear face of the idler gear.10. Install the idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so "V" mark (7) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K" marks (8) of the camshaft gear can be seen at the outer edges of the idler gear.End By:a. install fuel injection pump housing and rack actuator packageb. install timing gear cover