106673-2190 ZEXEL 9 400 617 219 BOSCH INJECTION-PUMP ASSEMBLY 9400617219 1066732190 me056796


106673-2190 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 617 219 9400617219
ZEXEL 106673-2190 1066732190
MITSUBISHI ME056796 me056796

Service parts 106673-2190 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 106061-5430
3. GOVERNOR 105487-4920
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 105100-7730
11. Nozzle and Holder
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:

106673-2190 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 617 219 9400617219
ZEXEL 106673-2190 1066732190
MITSUBISHI ME056796 me056796


Zexel num
Bosch num
Firm num
Name
106673-2190 
9 400 617 219 
ME056796  MITSUBISHI
INJECTION-PUMP ASSEMBLY
6D22T2 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   9.2
Pump speed r/min   700 700 700
Each cylinder's injection qty mm3/st.   142.6 139.1 146.1
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(9.2)
Pump speed r/min   700 700 700
Average injection quantity mm3/st.   142.6 141.6 143.6
Basic   *
Fixing the lever   *
Boost pressure kPa   26.7 26.7
Boost pressure mmHg   200 200
Injection quantity adjustment_04
Adjusting point   C
Rack position   5.2+-0.5
Pump speed r/min   225 225 225
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_05
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   120 100 140
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_06
Adjusting point   G
Rack position   R4(9.6)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   147.4 145.4 149.4
Fixing the lever   *
Boost pressure kPa   26.7 26.7
Boost pressure mmHg   200 200
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   R2(R1-0. 9)
Boost pressure kPa   9.3 9.3 9.3
Boost pressure mmHg   70 70 70
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   R2+0.5
Boost pressure kPa   11.3 10 12.6
Boost pressure mmHg   85 75 95
Boost compensator adjustment_03
Pump speed r/min   600 600 600
Rack position   R1(9.2)
Boost pressure kPa   13.3 13.3 13.3
Boost pressure mmHg   100 100 100

Test data Ex:

Governor adjustment

Test data 106673-2190
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)Tolerance for racks not indicated: +-0.05mm. (4)Boost compensator cancel stroke: BSL (5)Boost compensator stroke (6)Damper spring setting (7)When air cylinder is operating.
----------
BSL=1.6mm
----------

Timer adjustment

Test data 106673-2190
(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 106673-2190
F:Full speed I:Idle (1)Pump speed = aa (2)Pump speed = bb (3)Pump speed cc (4)Air cylinder's adjustable range
----------
aa=1160r/min bb=300r/min cc=735r/min
----------
a=(11deg)+-5deg b=(14deg)+-5deg c=(20deg)+-5deg d=(11deg)+-5deg

0000000901

Test data 106673-2190
F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=28deg+-5deg b=29deg+-3deg

Stop lever angle

Test data 106673-2190
S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Free (at delivery)
----------
aa=3.5-0.5mm
----------
a=38deg+7deg-5deg b=83deg+-5deg

0000001501 RACK SENSOR

Test data 106673-2190
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 2-STAGE CHANGEOVER DEVICE

Test data 106673-2190
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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0000001701 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=4.9+-0.1mm
----------

Timing setting

Test data 106673-2190
(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)




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