106871-7621 ZEXEL 9 400 618 222 BOSCH INJECTION-PUMP ASSEMBLY


Information injection-pump assembly

BOSCH 9 400 618 222 9400618222
ZEXEL 106871-7621 1068717621
MITSUBISHI ME090643 me090643

Service parts 106871-7621 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106087-7460
3. GOVERNOR 105489-1421
4. SUPPLY PUMP 105237-5580
5. AUTOM. ADVANCE MECHANIS 105681-0311
6. COUPLING PLATE 105663-0390
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105100-5831
11. Nozzle and Holder ME066499
12. Open Pre:MPa(Kqf/cm2) 17.7(180)/21.6(220)
13. NOZZLE-HOLDER 105030-4980
14. NOZZLE 105015-5440
15. NOZZLE SET

Include in #1:

106871-7621 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 222 9400618222
ZEXEL 106871-7621 1068717621
MITSUBISHI ME090643 me090643


Zexel num Bosch num Firm num Firm Name
106871-7621 
106873-2290 
9 400 618 222  ME090643  MITSUBISHI INJECTION-PUMP ASSEMBLY
8DC9T7 K 14CD INJECTION PUMP ASSY PE8P PE

Calibration Data:



Adjustment conditions
Test oil   ISO4113 or {SAEJ967d}
1404 Test oil
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 mm   8-3-600
Outer diameter - inner diameter - length (mm)
Overflow valve   131424-4620
Overflow valve opening pressure kPa   255 255 255
Overflow valve opening pressure kgf/cm2   2.6 2.6 2.6
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)   R
Right


Injection timing adjustment
Direction of rotation (viewed from drive side)   R
Right
Injection order   1-2-7-3- 4-5-6-8
Pre-stroke mm   4.8 4.75 4.85
Beginning of injection position   NO.1
Governor side
Difference between angles 1 deg.   45 44.5 45.5
Cyl.1-2
Difference between angles 2 deg.   90 89.5 90.5
Cal 1-7
Difference between angles 3 deg.   135 134.5 135.5
Cal 1-3
Difference between angles 4 deg.   180 179.5 180.5
Cal 1-4
Difference between angles 5 deg.   225 224.5 225.5
Cal 1-5
Difference between angles 6 deg.   270 269.5 270.5
Cal 1-6
Difference between angles 7 deg.   315 314.5 315.5
Cal 1-8


Injection quantity adjustment
Adjusting point   -
Rack position   10.3
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   131.8 127.9 135.7
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *


Injection quantity adjustment_02
Adjusting point   C
Rack position   6+-0.5
Pump speed r/min   225 225 225
Each cylinder's injection qty mm3/st.   17.5 14.9 20.1
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *


Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(10.3)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   131.8 130.8 132.8
Basic   *
Fixing the lever   *
Boost pressure kPa   29.3 29.3
Boost pressure mmHg   220 220


Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.1
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   138.6 134.6 142.6
Fixing the lever   *
Boost pressure kPa   29.3 29.3
Boost pressure mmHg   220 220


Injection quantity adjustment_05
Adjusting point   D
Rack position   -
Pump speed r/min   200 200 200
Average injection quantity mm3/st.   116 96 136
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0


Injection quantity adjustment_06
Adjusting point   E
Rack position   -
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   147.2 144.2 150.2
Fixing the lever   *
Rack limit   *


Injection quantity adjustment_07
Adjusting point   F
Rack position   R1+0.4
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   136.9 133.9 139.9
Fixing the lever   *
Boost pressure kPa   29.3 29.3
Boost pressure mmHg   220 220


Boost compensator adjustment
Pump speed r/min   450 450 450
Rack position   9.3
Boost pressure kPa   4 4 4
Boost pressure mmHg   30 30 30


Boost compensator adjustment_02
Pump speed r/min   450 450 450
Rack position   10.7
Boost pressure kPa   12.7 11.4 14
Boost pressure mmHg   95 85 105


Boost compensator adjustment_03
Pump speed r/min   450 450 450
Rack position   (11.3)
Boost pressure kPa   16 16 16
Boost pressure mmHg   120 120 120


Timer adjustment
Pump speed r/min   950--
Advance angle deg.   0 0 0
Remarks  
Start


Timer adjustment_02
Pump speed r/min   1100
Advance angle deg.   4 3.5 4.5
Remarks  
Finish

Test data Ex:



Governor adjustment

Test data 106871-7621 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)Boost compensator cancel stroke: BSL (5)RACK LIMIT (6)Boost compensator stroke: BCL (7)Damper spring setting (8)Rack difference between N = N1 and N = N2
----------
RT=1 TH=2.7mm BSL=1.6mm BCL=1+-0.1mm N1=1100r/min N2=700r/min
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Speed control lever angle

Test data 106871-7621 F:Full speed (1)Set the pump speed at aa (2)Set the pump speed at bb.
----------
aa=1250r/min bb=525r/min
----------
a=20deg+-5deg b=(13deg)+-5deg



0000000901

Test data 106871-7621 F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=35deg+-3deg



Stop lever angle

Test data 106871-7621 N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Rack position bb (4)Free (at shipping)
----------
aa=3.5-0.5mm bb=14.6mm
----------
a=47deg+7deg-5deg b=31.5deg+-5deg c=(10.5deg)



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
----------



0000001601 2-STAGE CHANGEOVER DEVICE

Test data 106871-7621 RFD governor 2 stage changeover mechanism adjustment outline (A) Bolt (B) bolt (c) Nut (D) Return spring (E) Bolt (F) Bolt (G) Screw (H) Bolt (I) Load lever (J) Speed lever (K) Air cylinder (M Air inlet Figure 1 is only for reference. Lever shape, etc, may vary. 1. Minimum-maximum speed specification adjustment (when running) (a) Without applying air to the air cylinder, loosen bolts (A) and (B). (1)High speed return L setting (a) In the speed range Nf~Nf - 300r/min, adjust using the speed adjusting bolt to determine the temporary beginning of high speed control speed. (b) Determine the rack position in the vicinity of Rf using the full load lever. (c) Increase speed and confirm return distance L. (d) Adjust using the tension lever bolt to obtain L. (2)Setting full load rack position Rf (a) Move the load control lever to the full side. (b) Adjust the full load adjusting bolt so that Rf can be obtained, then fix. (3)Setting the beginning of high speed operation Nf (a) Adjust using bolt (E) so that Nf can be obtained, and then fix. (4)Idle control setting (Re, Ni, Rc) (a) Set the speed at Ns + 200r/min and move the load control lever to the idle side. (b) Fix the lever in the position where Re can be obtained. (c) Next, decrease speed to Ni and screw in the idle spring. (d) Adjust to obtain rack position Ri. (e) Increase the speed and after confirming that the rack position is Re at Ns, set the speed at 0. (f) Confirm protrusion position Rc at idle. (5)Damper spring adjustment (a) Increase speed and set the speed at the rack position Rd - 0.1 mm (b) Set using the damper spring so that the rack position Rd can be obtained. (c) When Rd is not specified, Rd = Ri - 0.5 mm. (6)High speed droop confirmation (a) Return the load control lever to the full load lever position. (b) Increase the speed and confirm that Rf can be obtained at Nf r/min. (c) Confirm that speed is Nh at rack position Rh. 2. Variable speed specification adjustment (at operation) (a) Remove return spring (D). (b) Apply air pressure of 245~294 kPa {2.5~3 kg/cm2} to the air cylinder. (c) Perform the following adjustment in this condition. (1)Setting full load rack position Rf' (a) Pull the load lever to the idle side. (b) Obtain rack position Rf' using the nut (C). (Pump speed is Nf'-50 r/min.) (2)Setting full speed Nf' (a) Adjust using bolt (B) so that Nf can be obtained, and then fix. (3)Low speed side setting (a) At 350r/min, set bolt (F) at beginning of governor operation position, then fix. 3. Bolt (A) adjustment (1)Install return spring (D) and perform the adjustments below at air pressure 0. (a) Set at speed Nf using bolt (E). (b) Screw in bolt (A). (c) Screw in 1 more turn from the speed lever contact position (d) Fix bolt (A). (e) At this time confirm that the air cylinder's shaft moves approximately 1 mm towards the governor. 4. Lever operation confirmation using the air cylinder (1)Apply 588 kPa {6 kg/cm2} air pressure to the air cylinder. (2)Confirm that the cylinder piston is moved 50 mm by the spring (D).
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Timing setting

Test data 106871-7621 (1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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a=(40deg)





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