106661-2040 ZEXEL 9 400 616 589 BOSCH INJECTION-PUMP ASSEMBLY 9400616589 1066612040 me056800

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 616 589 9400616589

ZEXEL 106661-2040 1066612040

MITSUBISHI ME056800 me056800

Service parts 106661-2040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5520

3. GOVERNOR 105487-4100

4. SUPPLY PUMP 105207-1041

5. AUTOM. ADVANCE MECHANIS 105691-3370

6. COUPLING PLATE 105662-1100

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7731

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/24.5{250}

13. NOZZLE-HOLDER 105041-4420

14. NOZZLE

105015-6150

15. NOZZLE SET

Include in #1:

106661-2040 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 589 9400616589

ZEXEL 106661-2040 1066612040

MITSUBISHI ME056800 me056800

Zexel num

Bosch num

Firm num

Name

106661-2040
106661-2130

9 400 616 589

ME056800 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D22T6 * 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 131424-6920

Overflow valve opening pressure kPa 191 157 225

Overflow valve opening pressure kgf/cm2 1.95 1.6 2.3

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 1-5-3-6- 2-4

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 10.2

Pump speed r/min 650 650 650

Each cylinder's injection qty mm3/st. 138.5 135.1 141.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.5+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 17.5 14.9 20.1

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.2)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 138.5 137.5 139.5

Basic *

Fixing the lever *

Boost pressure kPa 27.3 27.3

Boost pressure mmHg 205 205

Injection quantity adjustment_04

Adjusting point D

Rack position 8.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 101.5 98.5 104.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 115 155

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position 8.6

Boost pressure kPa 5.3 5.3 5.3

Boost pressure mmHg 40 40 40

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(10.2)

Boost pressure kPa 14 14 14

Boost pressure mmHg 105 105 105

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Boost compensator cancel stroke: BSL (2)Damper spring setting: DL (3)Boost compensator stroke
----------
BSL=1.6mm DL=6.2-0.2mm
----------

Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(8.8deg) t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed
----------

----------
a=15.5deg+-5deg

0000000901

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

----------
a=28deg+-5deg b=31deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa (2)Free (at shipping)
----------
aa=3.4-0.5mm
----------
a=35.5deg+-5deg b=38.5deg+7deg-5deg

0000001501 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------

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
----------
N1=325+-5r/min Ra=6.2mm
----------

Timing setting

(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)-
----------
aa=11deg
----------
a=(7deg)