108622-2202 ZEXEL 9 400 619 145 BOSCH INJECTION-PUMP ASSEMBLY 9400619145 1086222202 me152177

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 145 9400619145

ZEXEL 108622-2202 1086222202

MITSUBISHI ME152177 me152177

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Cross reference number

BOSCH 9 400 619 145 9400619145

ZEXEL 108622-2202 1086222202

MITSUBISHI ME152177 me152177

Zexel num

Bosch num

Firm num

Name

108622-2202

9 400 619 145

ME152177 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D24 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

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 31

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 8.5 8.47 8.53

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 12.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 118 116.4 119.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8.4+-0.5

Pump speed r/min 390 390 390

Average injection quantity mm3/st. 14 12 16

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 8.4+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.5)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 118 117 119

Basic *

Fixing the lever *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 116.5 112.5 120.5

Fixing the lever *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

0000001601

Pre-stroke mm 8.5 8.47 8.53

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 8.5 8 9

Remarks
When the eccentric pin is tightened

_03

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 6.1 6.05 6.15

Output voltage V 2.45 2.44 2.46

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 8.5 8.47 8.53

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_05

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.5

Output voltage V 3 2.98 3

Confirmation *

_06

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.
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T1=AC06
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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.
----------
aa=45mm
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a=33.5deg+-5deg b=30.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At pump speed aa and rack position bb, set the stopper bolt. (Confirm non-injection.) (2)Normal engine position (Rack position corresponding to cc) (3)Use the hole above R = dd
----------
aa=1100r/min bb=3.5+-0.3mm cc=18mm dd=33.5mm
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a=41deg+-5deg b=25.5deg+-5deg c=(31deg)

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=4deg bb=8.5+-0.03mm
----------
a=(0deg) b=(44deg)

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 counterclockwise (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 clockwise 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.
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0000002201 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=8+-0.1mm
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0000002301 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(12.5)+1mm
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0000002401 LEVER

Speed lever cancel adjustment procedure (without dashpot) (A) Top lever (B) Bottom lever (C) Return spring 1. At governor adjustment (FULL adjustment) (1)Set high idle using the lever (A). (2)Confirm that lever (A) is not cancelled with lever (B).
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Information:

1. Exploded viewsIn the exploded views, the component parts are separated but so arranged to show their relationship to the whole. Index numbering is used to identify the parts and to indicate a sequence in which the parts are to be removed for disassembly, or they are to be installed for assembly. 2. SymbolsThe following symbols are used in this manual to emphasize important and critical instructions:
Indicates a condition that is essential to highlight.
Indicates a condition that can cause engine damage.
Indicates a condition that can cause personal injury or death.3. Definition of locational termsThe fan end is "front" and the flywheel end is "rear". The words "left" and "right" are as these directions would appear from the flywheel end.4. Dimensional or specification termsNominal size...Is the named size which has no specified limits of accuracy.Standard...Is the dimension of a part to be attained at the time of assembly, or the standard performance.Limit...Is the maximum or minimum permissible limit beyond which a part must be repaired or replaced.5. Tightening torquesTighten bolts, nuts, etc. in a wet condition (apply oil to threads) when specified as [WET]. Tighten them in a dry condition unless so specified. Use the general torques unless otherwise specified.MODEL IDENTIFICATION AND SERIAL NUMBER LOCATION
1. Model identification location(a) The model identification is embossed on the right side of the cylinder block, near the fuel injection pump mount.(b) The model identifications and displacements of the engines in current production are as listed below:
Model identification location(c) A scheme of coding used for identifying the engines in current production is as follows:
Example: Coded designation2. Serial Number LocationThe serial number is punched on the cylinder block, near the fuel injection pump mount.
Serial number locationCOMPONENT LOCATION
S3L/S3L2 S4L/S4L2SPECIFICATIONS
PERFORMANCE CURVES (ONE-HOUR RATING, WITH FAN)
PRIME POWER OUTPUT CHART