106661-2101 ZEXEL 9 400 616 593 BOSCH INJECTION-PUMP ASSEMBLY 9400616593 1066612101 me056851

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 616 593 9400616593

ZEXEL 106661-2101 1066612101

MITSUBISHI ME056851 me056851

Service parts 106661-2101 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-5590

3. GOVERNOR 105487-6700

4. SUPPLY PUMP 105217-6070

5. AUTOM. ADVANCE MECHANIS 105691-3370

6. COUPLING PLATE 105662-1100

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7730

11. Nozzle and Holder ME056804

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

13. NOZZLE-HOLDER 105031-4530

14. NOZZLE

105015-6150

15. NOZZLE SET

Include in #1:

106661-2101 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 593 9400616593

ZEXEL 106661-2101 1066612101

MITSUBISHI ME056851 me056851

Zexel num

Bosch num

Firm num

Name

106661-2101

9 400 616 593

ME056851 MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D22T2 K 14CA INJECTION PUMP ASSY PE6P,6PD PE

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
Inside diameter - outside 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 10.6

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 149 145.3 152.7

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 11.5 9.8 13.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 149 148 150

Basic *

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.35

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 147.5 145.5 149.5

Fixing the lever *

Boost pressure kPa 29.3 29.3

Boost pressure mmHg 220 220

Injection quantity adjustment_05

Adjusting point D

Rack position R1-1.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 117 114 120

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 131 91 171

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R2(R1-1. 7)

Boost pressure kPa 6 6 6

Boost pressure mmHg 45 45 45

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1-0.8

Boost pressure kPa 10 8.7 11.3

Boost pressure mmHg 75 65 85

Boost compensator adjustment_03

Pump speed r/min 700 700 700

Rack position R1(10.6)

Boost pressure kPa 16 16 16

Boost pressure mmHg 120 120 120

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Boost compensator cancel stroke: BSL (5)Boost compensator stroke: BCL (6)Damper spring setting
----------
RT=1 TH=2.9mm BSL=1.8mm BCL=1.7+-0.1mm
----------

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=(8.8)deg 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=14.5deg+-5deg

0000000901

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

----------
a=28deg+-5deg b=29.5deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa, stopper bolt setting (2)Free (at delivery)
----------
aa=3.8-0.5mm
----------
a=38deg+-5deg b=37.5deg+7deg-5deg

0000001501 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=325r/min Ra=5.7+-0.1mm
----------

0000001601 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
----------

0000001701 SPEED SENSOR

(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.)
----------
L=0.8~1mm
----------

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=9deg
----------
a=(7deg)