106971-2063 ZEXEL 9 400 618 684 BOSCH INJECTION-PUMP ASSEMBLY 9400618684 1069712063 me091900

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 684 9400618684

ZEXEL 106971-2063 1069712063

MITSUBISHI ME091900 me091900

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Buy INJECTION-PUMP ASSEMBLY 106971-2063 zexel genuine, new aftermarket engine parts with delivery

Service parts 106971-2063 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5580

3. GOVERNOR 105487-5282

4. SUPPLY PUMP 105237-1321

5. AUTOM. ADVANCE MECHANIS 105639-1210

6. COUPLING PLATE 105663-0550

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7971

11. Nozzle and Holder ME091276

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

13. NOZZLE-HOLDER 105030-4510

14. NOZZLE

105015-9440

15. NOZZLE SET

Include in #1:

106971-2063 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 684 9400618684

ZEXEL 106971-2063 1069712063

MITSUBISHI ME091900 me091900

Zexel num

Bosch num

Firm num

Name

106971-2063

9 400 618 684

ME091900 MITSUBISHI

INJECTION-PUMP ASSEMBLY
10DC11 * 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 1-2-7-8- 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 650 650 650

Each cylinder's injection qty mm3/st. 130 126.1 133.9

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. 17 14.4 19.6

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 650 650 650

Average injection quantity mm3/st. 130 129 131

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. 131.5 127.5 135.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point D

Rack position 11.4+-0. 1

Pump speed r/min 340 340 340

Average injection quantity mm3/st. 133 129 137

Fixing the lever *

Remarks
Startup boost setting

Injection quantity adjustment_06

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 155 135 175

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min (750)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Adjust with the load control lever in the full position (variable speed specification). (3)Tolerance for racks not indicated: +-0.05mm. (4)Deliver without the torque control spring operating. (5)Excess fuel setting for starting: SXL (N = N1) (6)Damper spring setting (7)When air cylinder is operating.
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SXL=11.4+-0.1mm N1=340r/min
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Speed control lever angle

F:Full speed I:Idle (1)- (2)Air cylinder's adjustable range (3)Pump speed = aa (4)Pump speed = bb (5)Pump speed cc
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aa=1200r/min bb=275r/min cc=800r/min
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a=(11deg) b=(11deg)+-5deg c=(22deg)+-5deg d=(7deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=27deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Free (at delivery) (4)Drive side (5)Use the hole at R = bb
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aa=3.7-0.5mm bb=35mm
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a=10.5deg+-5deg b=57deg+7deg-5deg

0000001501 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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0000001601 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=5.7+-0.1mm
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Timing setting

(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)

Information:

Camshaft
When reconditioning an engine, check the diameter of the camshaft bearing journals and the camshaft lobe height.Camshaft bearing journals have a diameter of 2.5000 .0005 in. (63.500 0.013 mm) and the minimum diameter worn is 2.4970 in. (63.424 mm).To find lobe lift (A) of camshaft, use the following procedure:1. Measure lobe height (B) of one exhaust and one intake lobe.2. Measure base circle (C) of one exhaust and one intake lobe.3. Subtract base circle (C) dimension (STEP 2) from lobe height (B) dimension (STEP 1). The difference is actual lobe lift (A).4. The specified (new) lobe lift (A) is: (a) Exhaust lobe ... .3071 in.(7.800 mm)(b) Intake lobe ... .3077 in.(7.816 mm)5. The maximum permissible difference between actual lobe lift (STEP 3) and specified lobe lift (STEP 4) is .025 in. (0.64 mm).
CAMSHAFT LOBE
A. Lobe lift. B. Lobe height. C. Base circle.With camshaft installed in the cylinder block, check end play. End play with new components should be .007 .003 in. (0.18 0.08 mm). The maximum permissible end play is .020 in. (0.51 mm).Camshaft Followers
Use an 8S2293 Magnet to remove the cam followers.
REMOVING CAM FOLLOWERSCam followers establish a wear pattern with the camshaft lobes. Identify and reinstall the followers removed. Dishing or circular wear pattern is allowed on the cam follower face, providing the wear face keeps a polished appearance. Replace the follower if the wear face is rough or shows signs of scuffing. A new follower can be used with an old camshaft, providing the lobe is in good condition. Put engine oil on the cam followers and the camshaft lobes before installing the cam followers. Use new cam followers with a new camshaft.Camshaft Gears
1. Remove screw (1) and washer (2) from end of camshaft.
REMOVING TIMING ADVANCE RETAINING SCREW
1. Screw. 2. Washer.2. Remove timing advance unit from the camshaft.3. Install puller (A), with spacer (C) over the shaft in the camshaft spacer (B) on spacer (C) as shown and remove the gear from the camshaft.
REMOVING GEAR (Typical Example)
A. 1P2321 Puller. B. 8S5579 Spacer. C. 9S9155 Spacer.To install the gear use the following procedure:1. Heat the gear to a temperature of approximately 400°F (204°C) before installing on the camshaft.
Do not heat the gear with a torch. Do not heat the gear to a temperature of more than 600°F (315°C). Heating the gear with a torch or to a temperature of more than 600°F (315°C) may cause the two drive dowels for the automatic timing advance to loosen and come out of the gear.
2. Align slot in gear hub with the pin in the camshaft. Install the gear on the camshaft with timing mark on gear aligned with timing mark on crankshaft gear. Be sure the gear is completly seated against the shoulder of the camshaft.
Do not drive the gear on the camshaft.
3. Align holes in weights with dowels in gear and install the automatic timing advance.4. Align pin (3) in washer with hole (4) in camshaft and install washer (2).5. Install screw (1) and