106861-2170 ZEXEL 9 400 617 973 BOSCH INJECTION-PUMP ASSEMBLY 9400617973 1068612170 me068083

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 617 973 9400617973

ZEXEL 106861-2170 1068612170

MITSUBISHI ME068083 me068083

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Cross reference number

BOSCH 9 400 617 973 9400617973

ZEXEL 106861-2170 1068612170

MITSUBISHI ME068083 me068083

Zexel num

Bosch num

Firm num

Name

106861-2170

9 400 617 973

ME068083 MITSUBISHI

INJECTION-PUMP ASSEMBLY
8DC9T * 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 131424-4620

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 11

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 136.3 133.3 139.3

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 10.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 124 120 128

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 5.3+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 18.5 15.9 21.1

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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 900

Advance angle deg. 0.8

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 3 2.5 3.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)At shipping (4)Idle sub spring setting: L1.
----------
K=10 L1=5-0.5mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)At shipping
----------

----------
a=3deg+-5deg b=27deg+-5deg c=(2deg)

Stop lever angle

N:Pump normal S:Stop the pump. (1)At shipping
----------

----------
a=19deg+-5deg b=46deg+-5deg

Timing setting

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

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

Information:

Rework Procedure
Replacement of Diesel Oxidation Catalyst (DOC):
1. Remove three 222-8823 Bolts and three 232-3209 Washers to separate the 360-8875 Bellows Tube Assembly from the 360-8849 Catalytic Converter Group. Refer to Image1.1.1.
Image1.1.1
2. Loosen the clamp. Remove the DOC from the Catalytic Converter Group. Refer to Images1.2.1 and 1.2.2.
Image1.2.1
Image1.2.2
3. Remove the ring from the DOC. Remove the clamp from the catalytic converter. Refer to Images1.3.1 and 1.3.2.
Image1.3.1
Image1.3.2
4. Remove the five screws and five washers from the insulation around the DOC. Remove the insulation from the DOC. The insulation will be reused. Refer to Images1.4.1 and 1.4.2.
Image1.4.1
Image1.4.2
5. Install the insulation that was removed from the old DOC on to the new DOC. Refer to Image1.5.1.
Image1.5.1
6. Clean the sealing surface of the DOC flange. Clean the sealing surface of the flange on the catalytic converter group. Clean the ring that was removed from the old DOC. Refer to Images1.6.1, 1.6.2, and 1.6.3.
Image1.6.1
Image1.6.2
Image1.6.3
7. Apply seal paste to both sides of the ring, to the flange surfaces of the new DOC, and the catalytic converter. Refer to Image1.7.1.
Note: Make sure to cover the complete ring and flange surfaces with seal paste when applying it.
Image1.7.1
8. Place the ring on the flange of the new DOC. Position the new DOC against the catalytic converter. Refer to Images1.8.1 and 1.8.2.
Image1.8.1
Image1.8.2
9. Orient the DOC so that it will line up correctly with the bellows tube. Install and orient the clamp in order to hold the new DOC in place. Apply sealing paste or high temperature grease to the bolt of the clamp. Tighten the clamp. Then reattach the DOC to the bellows tube. Refer to Image1.9.1.
Image1.9.1
10. Tap the clamp around the circumference to properly seat the clamp. Tighten the clamp to a specified torque of 18 N.m (13.3 ft-lb). Apply sealing paste or high temperature grease to the three 222-8823 Bolts to assemble the bellows. Refer to Image1.10.1.
Image1.10.1
11. Write down the number of active regenerations. This number can be found in the Monitor Service Menu in the Aftertreatment Status section. Enter this information to the claim story when you submit your claim. Refer to Image1.11.1.
Image1.11.1