Information injection-pump assembly
BOSCH
9 400 619 043
9400619043
ZEXEL
107692-2092
1076922092
MITSUBISHI
ME075607
me075607
Rating:
Cross reference number
BOSCH
9 400 619 043
9400619043
ZEXEL
107692-2092
1076922092
MITSUBISHI
ME075607
me075607
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
105780-8250
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-8420
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
17
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
5.6
5.57
5.63
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
13.4
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
122
120
124
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
7.7+-0.5
Pump speed
r/min
510
510
510
Average injection quantity
mm3/st.
10.5
8.7
12.3
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5.5+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.4)
.
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
122
121
123
Basic
*
Fixing the lever
*
Boost pressure
kPa
36
36
Boost pressure
mmHg
270
270
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.55
Pump speed
r/min
1350
1350
1350
Average injection quantity
mm3/st.
113
109
117
Fixing the lever
*
Boost pressure
kPa
36
36
Boost pressure
mmHg
270
270
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R2-1.4)
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
69
67
71
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
Injection quantity adjustment_06
Adjusting point
D
Rack position
(R1-0.55
)
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
118.5
114.5
122.5
Fixing the lever
*
Boost pressure
kPa
36
36
Boost pressure
mmHg
270
270
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
Boost compensator adjustment
Pump speed
r/min
250
250
250
Rack position
(R2-1.4)
Boost pressure
kPa
8
6.7
9.3
Boost pressure
mmHg
60
50
70
Boost compensator adjustment_02
Pump speed
r/min
250
250
250
Rack position
R2(R1-1.
3)
Boost pressure
kPa
22.7
22.7
22.7
Boost pressure
mmHg
170
170
170
0000001601
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.6
5.57
5.63
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_03
CU407980-224*
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
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)Boost compensator stroke: BCL
----------
T1=AC34 BCL=(1.4)+-0.1mm
----------
----------
T1=AC34 BCL=(1.4)+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Accelerator lever
(2)Use the hole at R = aa
(3)Stopper bolt set position 'H'
----------
aa=38mm
----------
a=32deg+-5deg b=39.5deg+-3deg
----------
aa=38mm
----------
a=32deg+-5deg b=39.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper bolt at rack position = bb, speed = cc and confirm non-injection.
----------
aa=30mm bb=0.5+-0.3mm cc=0r/min
----------
a=35deg+-5deg b=45deg+-5deg
----------
aa=30mm bb=0.5+-0.3mm cc=0r/min
----------
a=35deg+-5deg b=45deg+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper to align with the pointer's groove.
(4)Damper
(5)Pointer
(6)B.T.D.C.: aa
(7)Pre-stroke: bb
----------
aa=2deg bb=5.6+-0.03mm
----------
a=(0deg) b=(80deg)
----------
aa=2deg bb=5.6+-0.03mm
----------
a=(0deg) b=(80deg)
0000001401
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------
----------
----------
----------
0000001701
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001801
C:Shim
----------
----------
----------
----------
0000001901
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000002201 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=1350r/min Ra=R1(13.4)+1.55mm
----------
----------
N1=1350r/min Ra=R1(13.4)+1.55mm
----------
0000002301 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=290r/min Ra=7.7+-0.1mm
----------
----------
N1=290r/min Ra=7.7+-0.1mm
----------
0000002401 SPEED SENSOR
(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
----------
----------
L=0.8~1mm
----------
Information:
Oiler Feed Adjustment
If necessary, adjust the lubricator to release approximately four drops of fluid per minute into the starting motor air stream. Be sure there is NO fuel supply to the engine. 1. Push on the air start control lever (1) to crank the engine.2. Count the drops of fluid per minute that are released into the air stream. Turn the needle valve knob (3) counterclockwise to increase the flow and clockwise to decrease the flow of fluid into the air stream.Collector Bowl
Some air starters may be equipped with a collector bowl. The bowl collects used oil after the oil has lubricated the vanes. The bowl also collects moisture condensation from the compressed air. When the collector bowl becomes half full, drain the used lubricant. Never fill the lubricator bowl with oil from the collector bowl- use clean lubricant.Air Tank (If Equipped)
For good life of the air starting motor, the air supply must be free of dirt and water. The air starter requires adequate air pressure in order to operate.* Drain water from the air tank (if equipped). Open the drain valve on the bottom of the air tank to drain the condensation and oil carryover.* Check the air supply pressure. The air starting motor requires a minimum of 620 kPa (90 psi) of air pressure to operate properly. The maximum air pressure must not exceed 1550 kPa (225 psi). The normal air pressure will be 758 kPa (110 psi) to 965 kPa (140 psi).Engine Air Cleaner
Check Air Cleaner Service Indicator
Typical air cleaner indicator, mounted on the air cleaner housing. Your engine may be equipped with a different indicator.A service indicator (if equipped) may be mounted on the air cleaner or in a remote location. A colored piston showing in the window indicates the need for servicing the air cleaner. Observe the air cleaner service indicator. Clean or replace the air cleaner element when the yellow diaphragm enters the red zone or the red piston locks in the visible position. If the air cleaner indicator shows red at any time, clean the filter element or install a new air cleaner element.
Never service the air cleaner with the engine running since this will allow dirt to enter the engine.
If your air cleaner element becomes plugged, the air can split the element filter material. Unfiltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has air filter elements to service this unit. Contact your Caterpillar dealer for the correct filter element. If equipped with a Light Duty air cleaner element, refer to the 50 Hour interval for information.Single Stage Air Cleaner Elements
Remove and Install Air Cleaner Elements
1. Remove the air cleaner cover (1) and element (2).2. Seal the turbocharger air inlet (3) so that debris can not enter the inlet. Use tape, or secure a clean cloth over the opening.3. Clean the inside of the air cleaner cover and body.4. Inspect the replacement element for damage, dirt or debris.5. Remove the seal from the turbocharger inlet.6. Install a clean,
If necessary, adjust the lubricator to release approximately four drops of fluid per minute into the starting motor air stream. Be sure there is NO fuel supply to the engine. 1. Push on the air start control lever (1) to crank the engine.2. Count the drops of fluid per minute that are released into the air stream. Turn the needle valve knob (3) counterclockwise to increase the flow and clockwise to decrease the flow of fluid into the air stream.Collector Bowl
Some air starters may be equipped with a collector bowl. The bowl collects used oil after the oil has lubricated the vanes. The bowl also collects moisture condensation from the compressed air. When the collector bowl becomes half full, drain the used lubricant. Never fill the lubricator bowl with oil from the collector bowl- use clean lubricant.Air Tank (If Equipped)
For good life of the air starting motor, the air supply must be free of dirt and water. The air starter requires adequate air pressure in order to operate.* Drain water from the air tank (if equipped). Open the drain valve on the bottom of the air tank to drain the condensation and oil carryover.* Check the air supply pressure. The air starting motor requires a minimum of 620 kPa (90 psi) of air pressure to operate properly. The maximum air pressure must not exceed 1550 kPa (225 psi). The normal air pressure will be 758 kPa (110 psi) to 965 kPa (140 psi).Engine Air Cleaner
Check Air Cleaner Service Indicator
Typical air cleaner indicator, mounted on the air cleaner housing. Your engine may be equipped with a different indicator.A service indicator (if equipped) may be mounted on the air cleaner or in a remote location. A colored piston showing in the window indicates the need for servicing the air cleaner. Observe the air cleaner service indicator. Clean or replace the air cleaner element when the yellow diaphragm enters the red zone or the red piston locks in the visible position. If the air cleaner indicator shows red at any time, clean the filter element or install a new air cleaner element.
Never service the air cleaner with the engine running since this will allow dirt to enter the engine.
If your air cleaner element becomes plugged, the air can split the element filter material. Unfiltered air will drastically accelerate internal engine wear. Your Caterpillar dealer has air filter elements to service this unit. Contact your Caterpillar dealer for the correct filter element. If equipped with a Light Duty air cleaner element, refer to the 50 Hour interval for information.Single Stage Air Cleaner Elements
Remove and Install Air Cleaner Elements
1. Remove the air cleaner cover (1) and element (2).2. Seal the turbocharger air inlet (3) so that debris can not enter the inlet. Use tape, or secure a clean cloth over the opening.3. Clean the inside of the air cleaner cover and body.4. Inspect the replacement element for damage, dirt or debris.5. Remove the seal from the turbocharger inlet.6. Install a clean,