106671-7270 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1066717270

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106671-7270 1066717270

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Cross reference number

ZEXEL 106671-7270 1066717270

Zexel num

Bosch num

Firm num

Name

106671-7270
106671-7271

MITSUBISHI

INJECTION-PUMP ASSEMBLY
6D22T2 *

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 131424-4620

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 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 9.4

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 144 140.5 147.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point F

Rack position 5+-0.5

Pump speed r/min 500 500 500

Each cylinder's injection qty mm3/st. 16.5 14 19

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 144 143 145

Basic *

Fixing the lever *

Boost pressure kPa 48.7 48.7

Boost pressure mmHg 365 365

Injection quantity adjustment_04

Adjusting point B

Rack position R1(9.4)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 152.8 149.6 156

Difference in delivery mm3/st. 6.4 6.4 6.4

Fixing the lever *

Boost pressure kPa 48.7 48.7

Boost pressure mmHg 365 365

Injection quantity adjustment_05

Adjusting point D

Rack position 9.3

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 139.5 135.5 143.5

Fixing the lever *

Boost pressure kPa 32.7 32.7 32.7

Boost pressure mmHg 245 245 245

Injection quantity adjustment_06

Adjusting point C

Rack position 5.7+-0.5

Pump speed r/min 300 300 300

Each cylinder's injection qty mm3/st. 16.5 14 19

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
(check)

Injection quantity adjustment_07

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 115 95 135

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 7.9

Boost pressure kPa 6 6 6

Boost pressure mmHg 45 45 45

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 8.6

Boost pressure kPa 19.3 12.6 26

Boost pressure mmHg 145 95 195

Boost compensator adjustment_03

Pump speed r/min 600 600 600

Rack position 9.3

Boost pressure kPa 32.7 31.4 34

Boost pressure mmHg 245 235 255

Boost compensator adjustment_04

Pump speed r/min 600 600 600

Rack position R1(9.4)

Boost pressure kPa 35.3 35.3 35.3

Boost pressure mmHg 265 265 265

Timer adjustment

Pump speed r/min 450--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 400

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 800

Advance angle deg. 3 2.5 3.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Adjust with the load control lever in the full position (variable speed specification). (3)Lever ratio: RT (4)Target shim dimension: TH (5)Boost compensator cancel stroke: BSL (6)Boost compensator stroke: BCL (7)Damper spring setting: DL (8)When air cylinder is operating.
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RT=1 TH=2.5mm BSL=2.2mm BCL=1.5+-0.1mm DL=6.2-0.2mm
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Speed control lever angle

F:Full speed (1)Pump speed = aa
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aa=1150r/min
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a=(17deg)+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=51mm
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a=25deg+-5deg b=26.5deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Rack position bb (4)Free (at shipping)
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aa=4.1-0.5mm bb=13.3mm
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a=45deg+5deg-7deg b=26deg+-5deg c=(83deg)

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
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N1=400+-5r/min Ra=5.4mm
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0000001601 2-STAGE CHANGEOVER DEVICE

RFD governor 2 stage changeover mechanism adjustment outline (A) Bolt (B) bolt (c) Nut (D) Return spring (E) Bolt (F) Bolt (G) Screw (H) Bolt (I) Load lever (J) Speed lever (K) Air cylinder (M Air inlet Figure 1 is only for reference. Lever shape, etc, may vary. 1. Minimum-maximum speed specification adjustment (when running) (a) Without applying air to the air cylinder, loosen bolts (A) and (B). (1)High speed return L setting (a) In the speed range Nf~Nf - 300r/min, adjust using the speed adjusting bolt to determine the temporary beginning of high speed control speed. (b) Determine the rack position in the vicinity of Rf using the full load lever. (c) Increase speed and confirm return distance L. (d) Adjust using the tension lever bolt to obtain L. (2)Setting full load rack position Rf (a) Move the load control lever to the full side. (b) Adjust the full load adjusting bolt so that Rf can be obtained, then fix. (3)Setting the beginning of high speed operation Nf (a) Adjust using bolt (E) so that Nf can be obtained, and then fix. (4)Idle control setting (Re, Ni, Rc) (a) Set the speed at Ns + 200r/min and move the load control lever to the idle side. (b) Fix the lever in the position where Re can be obtained. (c) Next, decrease speed to Ni and screw in the idle spring. (d) Adjust to obtain rack position Ri. (e) Increase the speed and after confirming that the rack position is Re at Ns, set the speed at 0. (f) Confirm protrusion position Rc at idle. (5)Damper spring adjustment (a) Increase speed and set the speed at the rack position Rd - 0.1 mm (b) Set using the damper spring so that the rack position Rd can be obtained. (c) When Rd is not specified, Rd = Ri - 0.5 mm. (6)High speed droop confirmation (a) Return the load control lever to the full load lever position. (b) Increase the speed and confirm that Rf can be obtained at Nf r/min. (c) Confirm that speed is Nh at rack position Rh. 2. Variable speed specification adjustment (at operation) (a) Remove return spring (D). (b) Apply air pressure of 245~294 kPa {2.5~3 kg/cm2} to the air cylinder. (c) Perform the following adjustment in this condition. (1)Setting full load rack position Rf' (a) Pull the load lever to the idle side. (b) Obtain rack position Rf' using the nut (C). (Pump speed is Nf'-50 r/min.) (2)Setting full speed Nf' (a) Adjust using bolt (B) so that Nf can be obtained, and then fix. (3)Low speed side setting (a) At 350r/min, set bolt (F) at beginning of governor operation position, then fix. 3. Bolt (A) adjustment (1)Install return spring (D) and perform the adjustments below at air pressure 0. (a) Set at speed Nf using bolt (E). (b) Screw in bolt (A). (c) Screw in 1 more turn from the speed lever contact position (d) Fix bolt (A). (e) At this time confirm that the air cylinder's shaft moves approximately 1 mm towards the governor. 4. Lever operation confirmation using the air cylinder (1)Apply 588 kPa {6 kg/cm2} air pressure to the air cylinder. (2)Confirm that the cylinder piston is moved 50 mm by the spring (D).
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Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
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a=(7deg)

Information:

Disconnect all electrical power from the panel before making a panel cutout. Make sure the area around the panel cutout is clear. Take precautions to prevent metal cuttings from entering any components that are already installed in the panel. Failure to follow these instructions may result in personal injury or damage to the panel components.
Environmental Considerations
Mount the monitor in a panel or in an enclosure in order to protect the internal circuitry.Provide adequate ventilation in the enclosure. Also, consider heat produced by other devices in the enclosure. The ambient temperature around the monitor must be maintained between 5 °C (41 °F) and 50 °C (122 °F). Make sure that you provide provisions for accessing the back panel and side panels of the monitor. Installing components and removing components requires access to the panels. The floppy disk drive is also accessed through the panels. Refer to Illustration 1.
Illustration 1 g00857541
Mounting ClearancesNote: The dimensions in Illustration 1 are only applicable if the monitor has adequate ventilation. Cooling methods must be used in order to lower air temperature within the enclosure.Mounting Hardware
Table 1
Item Description Quantity Use For
Self-locking nuts #10-32 10 (8 required) Panel or enclosure mounting In addition to the tools that are required in order to make the cut for the panel, you will need the following tools:
Drill
9.525 mm (3/8 inch) socket
15 cm (6 inch) extension rod (minimum)
Socket driver (in/lb. torque wrench recommended)
RulerPanel Mounting
In order to install the monitor in a panel, perform the following procedure:
Cut an opening in the panel by using the dimensions that are provided. Drill eight 6.4 mm (0.25 inch) holes for the mounting studs. Refer to Installation, "Dimensions" for more information.
Make sure that the sealing gasket is properly positioned on the terminal. This gasket forms a compression seal. Do not use sealing compounds.
Place the monitor in the opening in the panel. Align the studs with the mounting holes.
Install the eight self-locking nuts. Hand tighten the self-locking nuts.
Illustration 2 g00857579
Torque Sequence
Alternately tighten the self-locking nuts with the 9.525 mm (3/8 inch) socket. Tighten the nuts until the monitor is held firmly against the panel. The amount of torque that is required increases significantly as the gasket reaches the proper compression. Tighten the nuts to a torque of 2.7 N m (24 lb in). Refer to Illustration 2 for the recommended tightening sequence.Note: Tighten the nuts to a torque of 2.7 N m (24 lb in) in order to provide a proper seal and prevent damage to the monitor.