Rating:
Information injection-pump assembly
ZEXEL
106861-2180
1068612180
Cross reference number
ZEXEL
106861-2180
1068612180
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-2-7-3-
4-5-6-8
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.4
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
140
135.8
144.2
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
7+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
18.5
16
21
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.4)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
140
139
141
Basic
*
Fixing the lever
*
Boost pressure
kPa
49.3
49.3
Boost pressure
mmHg
370
370
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(11.4)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
139
132.6
145.4
Difference in delivery
mm3/st.
12.8
12.8
12.8
Fixing the lever
*
Boost pressure
kPa
49.3
49.3
Boost pressure
mmHg
370
370
Injection quantity adjustment_05
Adjusting point
D
Rack position
11.2
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
128.5
124.8
132.2
Fixing the lever
*
Boost pressure
kPa
18.7
18.7
18.7
Boost pressure
mmHg
140
140
140
Injection quantity adjustment_06
Adjusting point
E
Rack position
-
Pump speed
r/min
200
200
200
Average injection quantity
mm3/st.
130
110
150
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
400
400
400
Rack position
9.9
Boost pressure
kPa
4
4
4
Boost pressure
mmHg
30
30
30
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Rack position
11.2
Boost pressure
kPa
18.7
17.4
20
Boost pressure
mmHg
140
130
150
Boost compensator adjustment_03
Pump speed
r/min
400
400
400
Rack position
(12.5)
Boost pressure
kPa
35.3
35.3
35.3
Boost pressure
mmHg
265
265
265
Timer adjustment
Pump speed
r/min
980--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
930
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
2
1.5
2.5
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)Boost compensator cancel stroke: BSL
(4)Boost compensator stroke
(5)When air cylinder is operating.
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BSL=1.6mm
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BSL=1.6mm
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Speed control lever angle
(1)Pump speed = aa
(2)Pump speed = bb
(3)Pump speed cc
(4)Possible adjusting range
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aa=1150r/min bb=655r/min cc=275r/min
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a=10deg b=(16deg)+-5deg c=8deg+-5deg d=10deg+-5deg
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aa=1150r/min bb=655r/min cc=275r/min
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a=10deg b=(16deg)+-5deg c=8deg+-5deg d=10deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
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a=10deg+-5deg b=34deg+-3deg
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a=10deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Fix using the stopper bolt.
(2)Rack position = aa
(3)Rack position bb
(4)Free (at shipping)
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aa=4.7-0.5mm bb=15.3mm
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a=43deg+7deg-5deg b=30deg+-5deg c=(10.5deg)
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aa=4.7-0.5mm bb=15.3mm
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a=43deg+7deg-5deg b=30deg+-5deg c=(10.5deg)
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=6.7mm
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N1=325+-5r/min Ra=6.7mm
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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=(40deg)
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a=(40deg)