107691-2102 ZEXEL 9 400 618 887 BOSCH INJECTION-PUMP ASSEMBLY 9400618887 1076912102 me075404


107691-2102 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 618 887 9400618887
ZEXEL 107691-2102 1076912102
MITSUBISHI ME075404 me075404

Cross reference number

BOSCH 9 400 618 887 9400618887
ZEXEL 107691-2102 1076912102
MITSUBISHI ME075404 me075404


Zexel num
Bosch num
Firm num
Name
107691-2102 
9 400 618 887 
ME075404  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D16T5 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   131424-8420
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
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
Adjusting point   -
Rack position   12.2
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   112 110 114
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
PS407980-224* V   1.75+-0. 01
PS407980-224* mm   3.6+-0.0 5
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   7.5+-0.5
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   10.8 9 12.6
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
PS407980-224* V   1.75+-0. 01
PS407980-224* mm   3.6+-0.0 5
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.2)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   112 111 113
Basic   *
Fixing the lever   *
Boost pressure kPa   34.7 34.7
Boost pressure mmHg   260 260
PS407980-224* V   1.75+-0. 01
PS407980-224* mm   3.6+-0.0 5
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+2
Pump speed r/min   1350 1350 1350
Average injection quantity mm3/st.   120 116 124
Fixing the lever   *
Boost pressure kPa   34.7 34.7
Boost pressure mmHg   260 260
PS407980-224* V   1.75+-0. 01
PS407980-224* mm   3.6+-0.0 5
Boost compensator adjustment
Pump speed r/min   300 300 300
Rack position   R2-1.1
Boost pressure kPa   6.7 5.4 8
Boost pressure mmHg   50 40 60
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   R2(R1-1. 4)
Boost pressure kPa   21.3 21.3 21.3
Boost pressure mmHg   160 160 160
Timer adjustment
Pump speed r/min   1150--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1100
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   3 2.5 3.5
Remarks
Finish
 
0000001601
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   1.17 1.16 1.18
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   2.8 2.6 3
Confirmation   *
_03
CU407980-224*   *
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Output voltage V   0.9
Confirmation of operating range   *

Test data Ex:

Governor adjustment

Test data 107691-2102
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Boost compensator stroke: BCL
----------
T1=AB39 BCL=1.1+-0.1mm
----------

Speed control lever angle

Test data 107691-2102
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting (3)Accelerator lever
----------
aa=38mm
----------
a=26deg+-5deg b=(36deg)+-3deg

Stop lever angle

Test data 107691-2102
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at speed = aa and rack position = bb. Confirm non-injection. (2)Use the hole above R = cc
----------
aa=0.5+-0.3mm bb=0r/min cc=40mm
----------
a=20deg+-5deg b=45deg+-5deg

0000001301

Test data 107691-2102
(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
----------
aa=2deg bb=5.6+-0.03mm
----------
a=(1deg)

0000001401

Test data 107691-2102
(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.
----------

----------

0000001701

Test data 107691-2102
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107691-2102
C:Shim
----------

----------

0000001901

Test data 107691-2102
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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0000002201 RACK SENSOR

Test data 107691-2102
(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=1350r/min Ra=R1(12.2)+2mm
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0000002301 SPEED SENSOR

Test data 107691-2102
(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
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L=0.8~1mm
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Have questions with 107691-2102?





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