Information injection-pump assembly
BOSCH
F 019 Z10 657
f019z10657
ZEXEL
106971-2051
1069712051
MITSUBISHI
ME091685
me091685
Rating:
Service parts 106971-2051 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME091276
12.
Open Pre:MPa(Kqf/cm2)
17.7(180)/21.6(220)
15.
NOZZLE SET
Include in #1:
106971-2051
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 657
f019z10657
ZEXEL
106971-2051
1069712051
MITSUBISHI
ME091685
me091685
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-4620
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-2-7-8-
5-6-3-4-
9-10
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 72 71.5 72.5
Cal 1-7 deg. 72 71.5 72.5
Difference between angles 3
Cal 1-8 deg. 117 116.5 117.5
Cal 1-8 deg. 117 116.5 117.5
Difference between angles 4
Cal 1-5 deg. 144 143.5 144.5
Cal 1-5 deg. 144 143.5 144.5
Difference between angles 5
Cal 1-6 deg. 189 188.5 189.5
Cal 1-6 deg. 189 188.5 189.5
Difference between angles 6
Cal 1-3 deg. 216 215.5 216.5
Cal 1-3 deg. 216 215.5 216.5
Difference between angles 7
Cal 1-4 deg. 261 260.5 261.5
Cal 1-4 deg. 261 260.5 261.5
Difference between angles 8
Cal 1-9 deg. 288 287.5 288.5
Cal 1-9 deg. 288 287.5 288.5
Difference between angles 9
Cal 1-10 deg. 333 332.5 333.5
Cal 1-10 deg. 333 332.5 333.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.7
Pump speed
r/min
650
650
650
Each cylinder's injection qty
mm3/st.
130
126.1
133.9
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.6+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
17
14.4
19.6
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.7)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
130
129
131
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(10.7)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
131.5
129.5
133.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
155
135
175
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
800--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
750
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
4.5
4
5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Deliver with positive torque control spring not operating
(3)Supplied with torque spring not set.
(4)Excess fuel setting for starting: SXL
(5)Damper spring setting
----------
SXL=11.4+-0.1mm
----------
----------
SXL=11.4+-0.1mm
----------
Speed control lever angle
F:Full speed
(1)Set the pump speed at aa
(2)Set the pump speed at bb.
----------
aa=1275r/min bb=895r/min
----------
a=19.5deg+-5deg b=(6deg)+-5deg
----------
aa=1275r/min bb=895r/min
----------
a=19.5deg+-5deg b=(6deg)+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=27deg+-3deg
----------
----------
a=10deg+-5deg b=27deg+-3deg
Stop lever angle
S:Stop the pump.
(1)Rack position = aa
(2)Stopper bolt setting
(3)Free (at shipping)
----------
aa=3.7-0.5mm
----------
a=10.5deg+-5deg b=57deg+7deg-5deg
----------
aa=3.7-0.5mm
----------
a=10.5deg+-5deg b=57deg+7deg-5deg
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=325r/min Ra=5.7+-0.1mm
----------
----------
N1=325r/min Ra=5.7+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
FEED ENGAGED
21. Slot. 22. Pin. 23. Knob. To set the feed mechanism into feed on later units, turn lever (A) up (the direction of arrow).
LATER FEED MECHANISM
A. Lever.Place adapter (24) into boring bar and tightening setscrew (25).
ADAPTER INSTALLED
24. 1P2364 Adapter. 25. Setscrew.Apply layout bluing to the bearing cap and bearing bore. Oil the centering rings. Do not use lubricant on the cutter. Use a one-half inch electric drill with universal joint (26) to feed tool through the bore. Service main bearings with .010 in. (0.25 mm) oversize outside diameter are available to permit the bore to be bored oversize. Bore the bore to 3.7175 .0005 in. (94.425 0.013 mm).
BORING BEARING BORE
26. 1P2363 Universal. If you use the later feed mechanism, the tool can be driven from either the boring bar or the feed mechanism.
DRIVING THROUGH FEED MECHANISM (Typical Example)
26. 1P2363 Universal.The bluing applied to the bearing bore indicates the condition of the bore at the corret bore size. If bluing shows an out of round condition, check the largest diameter (indicated by remaining bluing) in relation to the smallest diameter (indicated by lack of bluing). The difference of the two must not exceed .0010 in. (0.025 mm).If bluing indicates a step in the joint face, measure the diameter at the step in relation to the smallest diameter. A step of .0005 in. (0.013 mm) on one or both sides is permissible. A maximum of .0010 in. (0.025 mm) over the nominal finish bore diameter is permissible if within the described limits.To check the bore diameter, set the 1P3535 Dial Bore Gauge to 3.7175 in. (94.425 mm).
CHECKING BORE (Typical Example)Line Boring Main Bearing Bores
Line bore all main bearing bores if bearing caps or saddles are distorted.Clean bearing caps and saddles. Remove all nicks from pan rail. Plug oil holes in block with grease to prevent chips from entering oil passages.Place 1P2344 Centering Rings (1), with oiler (2) up, at each end of block. If an end bore is distorted, use the next good bore. There must be two good bores for locating centering rings.
CENTERING RINGS IN BLOCK
1. 1P2344 Centering Rings. 2. Oiler.Place original bearing caps (4) over the centering rings (1). Tighten bolts (3) hand tight.
CENTERING RINGS INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 4. Bearing caps.
BORING BAR INSTALLED
1. 1P2344 Centering Rings. 3. Bolts (four). 5. 1P2352 Boring Bar.Oil boring bar (5) and insert it through centering rings (1). Tighten bolts (3) to a minimum of 20 lb. ft. (25 N m) and a maximum of 50 lb. ft. (70 N m) while spinning bearing bar (5) to check for binding. Centering rings (1) must be seated in boring saddles after tightening.Slide boring bar (5) out of one end of block and install bearing assemblies (6) on boring bar (5). Slide boring bar (5) back through centering ring. Adjust bearing by tightening bolt (7) until bar begins to bind, then back off until boring bar (5) spins easily.
INSTALLING BEARING ASSEMBLIES
5. 1P2352 Boring Bar. 6. 1P2373 Bearing assembly