Information injection-pump assembly
ZEXEL
106871-7780
1068717780

Rating:
Service parts 106871-7780 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7(180)/21.6(220)
15.
NOZZLE SET
Include in #1:
106871-7780
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
106871-7780
1068717780
Zexel num
Bosch num
Firm num
Name
106871-7780
INJECTION-PUMP ASSEMBLY
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
1-2-7-3-
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
8.8
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
97
94.1
99.9
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.1+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
20
17
23
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(8.8)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
97
96
98
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(8.8)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
105.7
101.5
109.9
Difference in delivery
mm3/st.
8.4
8.4
8.4
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
135
115
155
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Timer adjustment
Pump speed
r/min
900
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
1.8
1.1
2.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
3.5
3.5
Timer adjustment_04
Pump speed
r/min
1150
Advance angle
deg.
6.5
6
7
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)Tolerance for racks not indicated: +-0.05mm.
(4)Excess fuel setting for starting: SXL
(5)Damper spring setting
(6)When air cylinder is operating.
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SXL=11.3+-0.1mm
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SXL=11.3+-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=1200r/min bb=275r/min cc=800r/min
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a=13deg b=8deg+-5deg c=13deg+-5deg d=23deg+-5deg
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aa=1200r/min bb=275r/min cc=800r/min
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a=13deg b=8deg+-5deg c=13deg+-5deg d=23deg+-5deg
0000000901

F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=23.5deg+-3deg
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a=10deg+-5deg b=23.5deg+-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)
----------
aa=4-0.5mm bb=11.7mm
----------
a=43deg+7deg-5deg b=21.5deg+-5deg c=(10.5deg)
----------
aa=4-0.5mm bb=11.7mm
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a=43deg+7deg-5deg b=21.5deg+-5deg c=(10.5deg)
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=5.6+-0.1mm
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N1=325r/min Ra=5.6+-0.1mm
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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=(40deg)
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a=(40deg)
Information:
2. Disconnect hose assemblies (2) and (4) from BrakeSaver control valve (1).3. Remove the bolts that hold elbow (3) and tube assembly (5) to BrakeSaver control valve (1). 4. Remove the four bolts (6) and remove BrakeSaver control valve (1) from the engine.Install Brakesaver Control Valve
1. Install O-ring seals (2) in BrakeSaver control valve (1).2. Make sure the seals are in position in the tube assembly and elbow.3. Put BrakeSaver control valve (1) in position on the engine and install the four bolts and lockwashers that hold it. 4. Install the bolts that hold tube assembly (6) and elbow (3) to the BrakeSaver control valve.5. Connect hose assemblies (4) and (5) to the BrakeSaver control valve.6. Fill the engine with oil to the correct level. Disassemble Brakesaver Control Valve
start by: a) remove BrakeSaver control valve 1. Remove plug (1), the O-ring seal, spring and plunger from the valve body. 2. Remove the bolts that hold cover (2) and valve group (10) in position. Remove cover (2), O-ring seal (3), valve group (10), gasket (9), slug (8), spring (7), stop (6), spring (5) and valve spool (4) from the valve body.3. Disassemble valve group (10) as follows: a) Remove the two plugs and O-ring seals from the ends of the valve body.b) Remove the two slugs and valve spool from the valve body.Assemble Brakesaver Control Valve
1. Install valve spool (3), slugs (2) and (5), the O-ring seals and plugs (1) and (6) in valve body (4) as shown. 2. Install the plunger, spring, O-ring seal and plug (16) in valve body (9).3. Install O-ring seal (8) and cover (7) on valve body (9).4. Install valve spool (10), spring (11), stop (12), spring (13) and slug (14) in valve body (9).5. Put gasket (15) and valve body (4) in position on valve body (9) and install the bolts to hold it.end by: a) install BrakeSaver control valve
1. Install O-ring seals (2) in BrakeSaver control valve (1).2. Make sure the seals are in position in the tube assembly and elbow.3. Put BrakeSaver control valve (1) in position on the engine and install the four bolts and lockwashers that hold it. 4. Install the bolts that hold tube assembly (6) and elbow (3) to the BrakeSaver control valve.5. Connect hose assemblies (4) and (5) to the BrakeSaver control valve.6. Fill the engine with oil to the correct level. Disassemble Brakesaver Control Valve
start by: a) remove BrakeSaver control valve 1. Remove plug (1), the O-ring seal, spring and plunger from the valve body. 2. Remove the bolts that hold cover (2) and valve group (10) in position. Remove cover (2), O-ring seal (3), valve group (10), gasket (9), slug (8), spring (7), stop (6), spring (5) and valve spool (4) from the valve body.3. Disassemble valve group (10) as follows: a) Remove the two plugs and O-ring seals from the ends of the valve body.b) Remove the two slugs and valve spool from the valve body.Assemble Brakesaver Control Valve
1. Install valve spool (3), slugs (2) and (5), the O-ring seals and plugs (1) and (6) in valve body (4) as shown. 2. Install the plunger, spring, O-ring seal and plug (16) in valve body (9).3. Install O-ring seal (8) and cover (7) on valve body (9).4. Install valve spool (10), spring (11), stop (12), spring (13) and slug (14) in valve body (9).5. Put gasket (15) and valve body (4) in position on valve body (9) and install the bolts to hold it.end by: a) install BrakeSaver control valve
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Mitsubishi
Mitsubishi
106871-7780
INJECTION-PUMP ASSEMBLY