107691-2600 ZEXEL 9 400 618 926 BOSCH INJECTION-PUMP ASSEMBLY 9400618926 1076912600 me072994

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 926 9400618926

ZEXEL 107691-2600 1076912600

MITSUBISHI ME072994 me072994

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Service parts 107691-2600 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-0300

3. GOVERNOR 105956-0070

4. SUPPLY PUMP 105237-6210

5. AUTOM. ADVANCE MECHANIS 105681-5700

6. COUPLING PLATE 105663-0840

7. COUPLING PLATE

8. _ 159600-9520

9. _

10. NOZZLE AND HOLDER ASSY 105110-7360

11. Nozzle and Holder ME075583

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

13. NOZZLE-HOLDER 105041-3110

14. NOZZLE

15. NOZZLE SET 105019-0340

Include in #1:

107691-2600 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 926 9400618926

ZEXEL 107691-2600 1076912600

MITSUBISHI ME072994 me072994

Zexel num

Bosch num

Firm num

Name

107691-2600

9 400 618 926

ME072994 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D17-1 K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 131424-8420

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

RED3 control unit part number 407910-2 470

RED3 rack sensor specifications mm 15

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 17

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 5.6 5.57 5.63

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Rack position (11)

Vist V 1.8 1.8 1.8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 120.5 119.5 121.5

Max. variation between cylinders % 0 -3 3

Basic *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

Injection quantity adjustment_02

Rack position (6)

Vist V 2.8 2.7 2.9

Pump speed r/min 440 440 440

Average injection quantity mm3/st. 15.5 13.7 17.3

Max. variation between cylinders % 0 -15 15

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5.5+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

Governor adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Governor adjustment_03

Pump speed r/min 1470

Advance angle deg. 3 2.5 3.5

Remarks
Finish

0000001201

CU407980-224* *

Actuator retarding type *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_03

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

Test data Ex:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=1mm bb=16mm
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a=31deg+-5deg b=29deg+-5deg

0000000901

(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)Pre-stroke: bb
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aa=5deg bb=5.6+-0.03mm
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a=(0deg)

Stop lever angle

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
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0000001301

A : Stopper pin B: Connector
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0000001401

C:Shim
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0000001501

A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
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0000001701

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 15 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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0000001901 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 (154610-0620) (1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01. (2)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)
----------
V1=1V
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Information:

start by:a) remove valve covers
Do not let the tops of the fuel nozzles turn when the fuel lines are loosened. The nozzles will be damaged if the top of the nozzles turn in the body.
1. Use tooling (A) to loosen fuel injection line nut (1) at the fuel injection nozzles. 2. Disconnect fuel injection line nut (2) from head adapter nut (3).3. Remove adapter nut (3) and the O-ring seal.4. Move adapter (4) out of the valve cover base, and remove fuel injection line (1). 5. If necessary, remove seal (5) from fuel injection line (1). 6. Remove bolt (7) that holds clamp (6). Clamp (6) cannot be removed until fuel injection nozzle (8) is lifted 25.0 mm (1.00 in.).7. Remove fuel injection nozzle (8) with tooling (B) as follows: a. Install 6V6983 Adapter and 6V4152 Screw (9) [part of tooling (B)] into fuel injection nozzle (8). b. Install 6V6982 Tube Assembly (11) over the 6V4152 Screw. Use 2S5658 Washer and 1B2406 Nut (10) on the 6V4152 Screw to pull fuel injection nozzle (8) from the adapter. Items (10) and (11) are part of tooling (B).
A replacement of compression seal washer (13) and of carbon dam seal (12) must be made each time the fuel injection nozzle is removed. Be sure that the replacement compression seal washer (13) is the same color code and part number as the original compression seal washer. If the wrong thickness washer is used, engine damage could occur. See the Specifications section of this book for more information.
8. Remove carbon dam seal (12) and compression seal washer (13) from fuel injection nozzle (8).Install Fuel Injection Nozzles
1. Use tool (D) to clean adapter bore (1) for the fuel injection nozzle. Use a tap driver to turn tool (D). 2. Install compression seal washer (3) on fuel injection nozzle (4).3. Use tool (A) to install carbon dam seal (2) on fuel injection nozzle (4). Refer to Special Instruction SEHS7292 for the use of tooling (C). 4. Install fuel injection nozzle (4) and clamp (5) as a unit. Install the bolt through the clamp into the adapter. 5. Install O-ring seal (6) on fuel injection line (7) and put clean diesel fuel on it. 6. Install fuel injection line (7). Move adapter (8) into position in the rocker arm cover base.
Do not let the tops of the fuel nozzles turn when the fuel lines are tightened. The nozzles will be damaged if the top of the nozzles turn in the body.
7. Use tooling (B) to tighten the inner fuel line nuts to a torque of 41 7 N m (30 5 lb.ft.). 8. Put clean diesel fuel oil on O-ring seal (11). Install O-ring seal (11) and nut (10). Tighten nut (10) to a torque of 30 5 N m (22 4 lb.ft.).9. Install nut (9) for the fuel injection line, and tighten the fuel injection line nut to a torque of 41 7 N m (30 5 lb.ft.).end by:a)