106861-2480 ZEXEL 9 400 617 991 BOSCH INJECTION-PUMP ASSEMBLY 9400617991 1068612480 me098599


106861-2480 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 617 991 9400617991
ZEXEL 106861-2480 1068612480
MITSUBISHI ME098599 me098599

Service parts 106861-2480 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106086-5650
3. GOVERNOR 105487-4860
4. SUPPLY PUMP 105237-1321
5. AUTOM. ADVANCE MECHANIS 105636-1910
6. COUPLING PLATE 105663-0260
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-4972
11. Nozzle and Holder ME066034
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105030-4990
14. NOZZLE 105015-4580
15. NOZZLE SET

Include in #1:

106861-2480 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 617 991 9400617991
ZEXEL 106861-2480 1068612480
MITSUBISHI ME098599 me098599


Zexel num
Bosch num
Firm num
Name
106861-2480 
9 400 617 991 
ME098599  MITSUBISHI
INJECTION-PUMP ASSEMBLY
8DC9T K 14CD INJECTION PUMP ASSY PE8P PE

Calibration Data:

Adjustment conditions
Test oil
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
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
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   4.8 4.75 4.85
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   A
Rack position   9.6
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   137.5 134.5 140.5
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   C
Rack position   6.3+-0.5
Pump speed r/min   225 225 225
Average injection quantity mm3/st.   12 9.4 14.6
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
Injection quantity adjustment_03
Adjusting point   D
Rack position   -
Pump speed r/min   200 200 200
Average injection quantity mm3/st.   205 185 225
Fixing the lever   *
Remarks
After startup boost setting
 
Timer adjustment
Pump speed r/min   1100++
Advance angle deg.   0 0 0
Remarks
Do not advance until starting N = 1100.
 
Timer adjustment_02
Pump speed r/min   -
Advance angle deg.   3.5 3.5 3.5
Remarks
Measure the actual speed, stop
 

Test data Ex:

Governor adjustment

Test data 106861-2480
N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (5)Damper spring setting
----------
RT=1 TH=2.9mm SXL=9.8+-0.1mm
----------

Speed control lever angle

Test data 106861-2480
F:Full speed
----------

----------
a=(13.5deg)+-5deg

0000000901

Test data 106861-2480
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=31deg+-3deg

Stop lever angle

Test data 106861-2480
N:Pump normal S:Stop the pump. (1)Drive side (2)Use the hole at R = aa (3)Rack position bb (4)Stopper bolt setting
----------
aa=32mm bb=3.5-0.5mm
----------
a=10.5deg+-5deg b=57.5deg+7deg-5deg

0000001501 RACK SENSOR

Test data 106861-2480
V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------

Timing setting

Test data 106861-2480
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)




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