106676-2630 ZEXEL 9 400 617 454 BOSCH INJECTION-PUMP ASSEMBLY 9400617454 1066762630 me440970

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 454 9400617454

ZEXEL 106676-2630 1066762630

MITSUBISHI ME440970 me440970

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Service parts 106676-2630 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-6601

3. GOVERNOR 105407-8170

4. SUPPLY PUMP

105237-4790

5. AUTOM. ADVANCE MECHANIS 105691-4220

6. COUPLING PLATE 105663-0800

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

105110-8122

11. Nozzle and Holder ME440089

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-4111

14. NOZZLE

15. NOZZLE SET 105019-2670

Include in #1:

106676-2630 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 617 454 9400617454

ZEXEL 106676-2630 1066762630

MITSUBISHI ME440970 me440970

Zexel num

Bosch num

Firm num

Name

106676-2630

9 400 617 454

ME440970 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D24TL K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

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 131424-4420

Overflow valve opening pressure kPa 157 157 157

Overflow valve opening pressure kgf/cm2 1.6 1.6 1.6

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)
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 3.9 3.85 3.95

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 12.1

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 155 152 158

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 30 30

Boost pressure mmHg 225 225

Injection quantity adjustment_02

Adjusting point -

Rack position 8+-0.5

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 16 13.4 18.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-0.55

Boost pressure kPa 7.3 4.6 10

Boost pressure mmHg 55 35 75

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(12.1)

Boost pressure kPa 16.7 10 23.4

Boost pressure mmHg 125 75 175

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Boost compensator stroke (3)Main spring setting (4)Set idle sub-spring (5)Rack difference between N = N1 and N = N2
----------
K=11 N1=1000r/min N2=375r/min
----------

Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Base lever only
----------

----------
a=(3deg)+-5deg b=(20deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)No return spring (2)Set the outer screw where it contacts the inside (seal at delivery) (3)Rack position = aa, speed = bb (stamp at delivery) (4)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=17mm
----------
a=14deg+-5deg b=70deg+-5deg

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A) After adjusting the boost compensator, tighten the bolts to remove the heads. (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2 maximum)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------

0000001601 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=1000r/min Ra=12.1mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=5deg
----------
a=(2deg)

Information:

1. Disconnect the fuel outlet line (1) and fuel inlet line (3) from the priming pump.2. Disconnect the fuel line (2) from pump.3. Remove the bolts (4) from pump.4. Remove the fuel transfer pump.5. Remove the fuel lines (1) and (3) from pump.Install Fuel Transfer Pump
1. Install the two fuel lines in transfer pump.2. Put the fuel transfer pump in position in the accessory drive housing, and install the two bolts.3. Connect the two fuel lines to priming pump.4. Connect the fuel line to transfer pump.Disassemble Fuel Transfer Pump
start by: a) remove fuel transfer pump 1. Remove the nut (2), gear (3), and key.2. Remove the cage (1). Remove the O-ring seals from the cage.3. Use tool setup (A) to remove the bearing and seals from cage (1).4. Remove the cover (4).
Be careful during disassembly and assembly of pump to prevent damage to the contacting surfaces of the cover (4) and the pump body.
5. Remove the bolt (5), spring, and ball for the check valve for the priming pump. 6. Remove the gear (7), and gear and shaft assembly (6) from pump body. 7. Use tool setup (A) to remove the bearing from the pump body.Assemble Fuel Transfer Pump
1. Clean all parts thoroughly before assembling the pump. 2. Use tool setup (A) to install the bearing in the pump body.3. Put the gear, and gear and shaft assembly in position in pump body.4. Put a thin amount of 8S6747 Liquid Gasket Material on the face of body assembly that is against the cover.
Do not let the liquid gasket material get into the pump.
5. Put the cover into position on pump body and install the bolts. The gear and shaft assembly must turn freely after the bolts in cover have been tightened.6. Install the check valve ball, spring, and bolt for the priming pump in the cover. 7. Use tool setup (B) to install the seals in cage. Install the two seals with the lips of seals toward each other.8. Use tool setup (A) to install the bearing in cage assembly. Install the O-ring seals on cage. 9. Put clean oil on O-ring seals and lips of seals. 10. Put the cage assembly in position, and install the woodruff key, gear, and nut. Tighten nut to 22 5 lb.ft. (3.0 0.7 mkg).end by: a) install fuel transfer pump