106873-2381 ZEXEL 9 400 618 354 BOSCH INJECTION-PUMP ASSEMBLY 9400618354 1068732381 me092079

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Information injection-pump assembly

BOSCH 9 400 618 354 9400618354

ZEXEL 106873-2381 1068732381

MITSUBISHI ME092079 me092079

Service parts 106873-2381 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7890

3. GOVERNOR 105489-3190

4. SUPPLY PUMP 105237-1321

5. AUTOM. ADVANCE MECHANIS 105681-1020

6. COUPLING PLATE 105663-0390

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7011

11. Nozzle and Holder ME091308

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-4980

14. NOZZLE 105015-8500

15. NOZZLE SET

Include in #1:

106873-2381 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 354 9400618354

ZEXEL 106873-2381 1068732381

MITSUBISHI ME092079 me092079

Zexel num

Bosch num

Firm num

Name

106873-2381

9 400 618 354

ME092079 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9T7 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 -

Rack position 10.8

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 134.6 130.6 138.6

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 15.8 13.4 18.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.8)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 134.6 133.6 135.6

Basic *

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 138.8 134.8 142.8

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Injection quantity adjustment_05

Adjusting point D

Rack position -

Pump speed r/min 200 200 200

Average injection quantity mm3/st. 97 57 137

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point E

Rack position R1+0.35

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 142.8 139.8 145.8

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Injection quantity adjustment_07

Adjusting point F

Rack position R1-0.9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 116.8 114.8 118.8

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_08

Adjusting point G

Rack position 12.2+-0. 1

Pump speed r/min 200 200 200

Average injection quantity mm3/st. 142 132 152

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Rack limit *

Boost compensator adjustment

Pump speed r/min 450 450 450

Rack position R1-0.9

Boost pressure kPa 3.3 3.3 5.3

Boost pressure mmHg 25 25 40

Boost compensator adjustment_02

Pump speed r/min 450 450 450

Rack position R1(10.8)

Boost pressure kPa 10 8.7 11.3

Boost pressure mmHg 75 65 85

Boost compensator adjustment_03

Pump speed r/min 450 450 450

Rack position (11.7)

Boost pressure kPa 15.3 15.3 15.3

Boost pressure mmHg 115 115 115

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

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: RAL (6)Boost compensator stroke (7)Damper spring setting (8)Rack difference between N = N1 and N = N2
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RT=1 TH=2.4mm BSL=1.4mm RAL=12.2+-0.1mm N1=990r/min N2=700r/min
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Speed control lever angle

F:Full speed (1)Stopper bolt setting (2)Stopper bolt setting (3)Set the pump speed at aa
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aa=525r/min
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a=16deg+-5deg b=(13deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=30.5deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa (non-injection rack position) (2)Stopper bolt setting (3)Free (at delivery)
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aa=3.3-0.5mm
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a=10.5deg+-5deg b=58deg+7deg-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
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N1=325r/min Ra=5.8+-0.1mm
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0000001601 2-STAGE CHANGEOVER DEVICE

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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