Rating:
Information injection-pump assembly
ZEXEL
106651-2380
1066512380
Cross reference number
ZEXEL
106651-2380
1066512380
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
5.1
5.05
5.15
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.1
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
140
136.5
143.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.3+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
18.6
15.9
21.3
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.1)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
140
139
141
Basic
*
Fixing the lever
*
Boost pressure
kPa
51.3
51.3
Boost pressure
mmHg
385
385
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(12.1)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
139
135
143
Difference in delivery
mm3/st.
8
8
8
Fixing the lever
*
Boost pressure
kPa
51.3
51.3
Boost pressure
mmHg
385
385
Injection quantity adjustment_05
Adjusting point
D
Rack position
11.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
121
117.4
124.6
Fixing the lever
*
Boost pressure
kPa
26
26
26
Boost pressure
mmHg
195
195
195
Injection quantity adjustment_06
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
110
90
130
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
F
Rack position
R2(10.8)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
117
113.5
120.5
Fixing the lever
*
Remarks
Adjust using 2-stage changeover device.
Adjust using 2-stage changeover device.
Boost compensator adjustment
Pump speed
r/min
600
600
600
Rack position
10.4
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
11.5
Boost pressure
kPa
26
24.7
27.3
Boost pressure
mmHg
195
185
205
Boost compensator adjustment_03
Pump speed
r/min
600
600
600
Rack position
R1(12.1)
Boost pressure
kPa
38
31.3
44.7
Boost pressure
mmHg
285
235
335
Timer adjustment
Pump speed
r/min
450--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
400
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
720
Advance angle
deg.
2.5
2
3
Remarks
Finish
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)Damper spring setting: DL
(7)Boost compensator stroke: BCL
(8)When air cylinder is operating.
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RT=1 TH=2.4mm BSL=2mm DL=6.8-0.2mm BCL=1.7+-0.1mm
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RT=1 TH=2.4mm BSL=2mm DL=6.8-0.2mm BCL=1.7+-0.1mm
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Speed control lever angle
F:Full speed
I:Idle
(1)Pump speed = aa
(2)Pump speed = bb
(3)Pump speed cc
(4)Air cylinder's adjustable range
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aa=1150r/min bb=300r/min cc=(1100)r/min
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a=(2deg)+-5deg b=(10deg)+-5deg c=(25deg)+-5deg d=(2deg)
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aa=1150r/min bb=300r/min cc=(1100)r/min
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a=(2deg)+-5deg b=(10deg)+-5deg c=(25deg)+-5deg d=(2deg)
0000000901
F:Full load
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt setting
----------
aa=43mm
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a=21deg+-5deg b=37deg+-3deg
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aa=43mm
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a=21deg+-5deg b=37deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Free (at shipping)
(2)Rack position = aa
(3)Rack position = bb, set the stopper bolt.
(4)-
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aa=14mm bb=4.9-0.5mm
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a=45deg+5deg-7deg b=25.5deg+-5deg c=(80.5deg)
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aa=14mm bb=4.9-0.5mm
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a=45deg+5deg-7deg b=25.5deg+-5deg c=(80.5deg)
0000001501 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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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
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N1=325+-5r/min Ra=6mm
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N1=325+-5r/min Ra=6mm
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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=(6deg)
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a=(6deg)