106971-2021 ZEXEL 9 400 618 682 BOSCH INJECTION-PUMP ASSEMBLY 9400618682 1069712021 me090925

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 682 9400618682

ZEXEL 106971-2021 1069712021

MITSUBISHI ME090925 me090925

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Service parts 106971-2021 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5410

3. GOVERNOR 105487-4082

4. SUPPLY PUMP 105237-1321

5. AUTOM. ADVANCE MECHANIS 105639-1170

6. COUPLING PLATE 105663-0550

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7150

11. Nozzle and Holder ME060110

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

13. NOZZLE-HOLDER 105031-4500

14. NOZZLE 105015-6580

15. NOZZLE SET

Include in #1:

106971-2021 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 682 9400618682

ZEXEL 106971-2021 1069712021

MITSUBISHI ME090925 me090925

Zexel num

Bosch num

Firm num

Name

106971-2021
106971-2050

9 400 618 682

ME090925 MITSUBISHI

INJECTION-PUMP ASSEMBLY
10DC11 K 14CE INJECTION PUMP ASSY PE10P 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 1-2-7-8- 5-6-3-4- 9-10

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. 72 71.5 72.5

Difference between angles 3
Cal 1-8 deg. 117 116.5 117.5

Difference between angles 4
Cal 1-5 deg. 144 143.5 144.5

Difference between angles 5
Cal 1-6 deg. 189 188.5 189.5

Difference between angles 6
Cal 1-3 deg. 216 215.5 216.5

Difference between angles 7
Cal 1-4 deg. 261 260.5 261.5

Difference between angles 8
Cal 1-9 deg. 288 287.5 288.5

Difference between angles 9
Cal 1-10 deg. 333 332.5 333.5

Injection quantity adjustment

Adjusting point -

Rack position 10.7

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 129 125.1 132.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.6+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.7)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129 128 130

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.7)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 133 129 137

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 145 105 185

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Excess fuel setting for starting: SXL (2)Damper spring setting: DL
----------
SXL=11.4+-0.1mm DL=4.8-0.2mm
----------

Speed control lever angle

F:Full speed (1)Set the pump speed at aa (2)Set the pump speed at bb.
----------
aa=(1150)r/min bb=650r/min
----------
a=19deg+-5deg b=6deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=10deg+-5deg b=27deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Free (at shipping)
----------
aa=3.7-0.5mm
----------
a=10.5deg+-5deg b=57deg+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
----------
N1=325+-5r/min Ra=5.7mm
----------

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:

Introduction
Tools are now available for the 6V4830 Fixture Group for removal and replacement of tappet springs on 3500 Unit Injectors.
Type 2 Fuel Injector. (1) Spring. (2) Rack Bar.
(3) 6V4830 Fixture Group. (4) 4C9279 Plate Assembly.Use fixture group (3) and plate assembly (4) along with the procedure in this instruction to remove and install tappet springs on injectors.Do not perform any procedure, outlined in this publication, or order any parts until you read and understand the information contained within.Removal and Installation of Fuel Injector Tappet Springs
Take care not to damage, drop, or jar the internal parts of the injector. Injector parts must be clean when reassembled. Place a light coating of clean diesel fuel, kerosene, or calibration fluid on the moving internal components during assembly.
* Clean the outside of the injector before disassembly. Install good O-ring seals on the injector and then install a 6V4172 Cleaning Sleeve. Wash the outside of the injector with solvents and a brush. Dry with pressure air.
Pressure air can cause personal injury. When using pressure air for cleaning, wear a protective face shield, protective clothing and protective shoes.The maximum air pressure must be below 205 kPa (30 psi) for cleaning purposes.
1. Remove existing plate and secure plate assembly (4) to fixture group (3).2. Remove O-ring seals from the injector prior to placing injector into fixture.3. Place injector into fixture with spring up as shown. Rack bar (2) on injector is to be extended out so that it is locked into position by two pins on plate assembly (4). 4. Using the handle of the fixture group, compress injector spring (tappet) (5) so that lock pin (6) can be pushed IN to release the tappet assembly from the injector body. 5. Remove tappet assembly from the injector body. Remove and discard old spring. Place the injector plunger on a soft clean cloth to avoid handling the plunger. Excessive handling will remove the fuel on the plunger and may result in corroding the plunger if it is left out for an extended period of time.6. Install new spring on injector body. 7. Locate the punched dot (.)(7) on the top end of the gear after it is pulled out of the body. Using a yellow magic marker, paint the whole length of the tooth that is 180° opposite the punched dot.
Injector Assembly (shown without spring).8. As the tappet/plunger assembly is inserted into the body, the yellow colored tooth on the gear should be visible in the center of the slot for the tappet lock pin.
Injector Assembly (shown without spring). 9. With the colored tooth visible in the slot of the injector body, a pin or long narrow screw driver is needed to position the gear to engage rack and pinion teeth after which the tappet assembly will drop into place.10. Using the 6V4830 Fixture Group, apply pressure on tappet (5) to compress the spring so the pin pops out and locks the tappet assembly in place.11. Remove the injector from the fixture. Push and pull the