108822-2474 ZEXEL 9 400 619 296 BOSCH INJECTION-PUMP ASSEMBLY 9400619296 1088222474 me094564

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 296 9400619296

ZEXEL 108822-2474 1088222474

MITSUBISHI ME094564 me094564

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Service parts 108822-2474 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108082-3510

3. GOVERNOR 105952-1682

4. SUPPLY PUMP 105237-4800

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0990

7. COUPLING PLATE

8. _ 159600-5322

9. _ 156641-0620

10. NOZZLE AND HOLDER ASSY 105110-7382

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER 105041-4121

14. NOZZLE

15. NOZZLE SET 105019-0350

Include in #1:

108822-2474 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 296 9400619296

ZEXEL 108822-2474 1088222474

MITSUBISHI ME094564 me094564

Zexel num

Bosch num

Firm num

Name

108822-2474
108822-2940

9 400 619 296

ME094564 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC11 K 14CQ INJECTION PUMP ASSY TICS HD-TI8F TICS

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

RED3 control unit part number 407910-2 470

RED3 rack sensor specifications mm 15

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

Digi switch no. 42

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 8.5 8.47 8.53

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25

Difference between angles 3
Cal 1-3 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-8 deg. 315 314.75 315.25

Injection quantity adjustment

Rack position (11.5)

Vist V 1.69 1.69 1.69

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 122 121 123

Max. variation between cylinders % 0 -3 3

Basic *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 6.1+-0.0 5

Injection quantity adjustment_02

Rack position (7.5)

Vist V 2.5 2.4 2.6

Pump speed r/min 340 340 340

Average injection quantity mm3/st. 23.5 20.9 26.1

Max. variation between cylinders % 0 -15 15

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 8.4+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

0000001201

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:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=16mm bb=1mm
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a=12deg+-5deg b=29deg+-5deg

0000000901

(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
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a=(45deg) b=(44deg)

0000001501

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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0000001701

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 15 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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0000001901 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 (154610-0620) (1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01. (2)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)
----------
V1=1V
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Information:

1. Disconnect hose (1) at governor control cylinder (2).2. Remove pin (4).3. Remove governor control cylinder (2).4. Note the position of linkage (3) in the lever, and remove linkage (3). The following steps are for installation of the governor control cylinder.5. Adjust linkage (3) so the distance between rod end centers is 84.07 mm (3.309 in).6. Install linkage (3) in its original position in the lever.7. Be sure lever (5) on the governor shaft is at 15 degrees from vertical (CW when viewed from the left side of the machine) with engine at low idle.8. Install control cylinder (2). Install pin (4) through link (3) and lever (5).9. Connect hose (1) to governor control cylinder (2).10. Adjust linkage (3) so lever (5) is at low idle when governor control cylinder is fully retracted.Disassemble & Assemble Governor Control Cylinder
Start By:a. remove governor control cylinder 1. Remove cover (1).
A spring force of 44.5 N (10 lb) will be released when the bolt that holds piston (8) is removed. Hold the components of the governor control cylinder to prevent unexpected movement of components and personal injury.
2. Remove the bolt that holds piston (6), and remove the piston and springs.3. Remove O-ring seal (2) and sleeve (5).4. Remove seals (3) and (4) from piston (6). The following steps are for the assembly of the governor control cylinder.5. Install lip-type seal (3) and "T" seal on the piston (6). Install the lip-type seal with the lip facing the cylinder pressure source.6. Install shell (5) in the air chamber body.7. Put 5P-0960 Multipurpose Grease inside the shell.8. Carefully install piston (6) and springs into the air chamber body.9. Install the bolt to hold the piston.10. Install O-ring seal (2) and cover (1).End By:a. install governor control cylinder