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


106661-2040 INJECTION-PUMP ASSEMBLY
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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

Test data 106661-2040
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

Test data 106661-2040
(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

Test data 106661-2040
F:Full speed
----------

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

0000000901

Test data 106661-2040
F:Full load I:Idle (1)Stopper bolt setting
----------

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

Stop lever angle

Test data 106661-2040
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

Test data 106661-2040
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

Test data 106661-2040
(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)




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