106873-2171 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1068732171

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 106873-2171 1068732171

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Cross reference number

ZEXEL 106873-2171 1068732171

Zexel num

Bosch num

Firm num

Name

106873-2171

INJECTION-PUMP ASSEMBLY

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 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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point -

Rack position 9.7

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 109 105.7 112.3

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 12 10.2 13.8

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.7)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 109 108 110

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.6

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 106 104 108

Fixing the lever *

Injection quantity adjustment_05

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 125 85 165

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 930--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 880

Advance angle deg. 0.5

Load 3/4

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

Load 4/4

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)Tolerance for racks not indicated: +-0.05mm. (6)Excess fuel setting for starting: SXL (7)Damper spring setting (8)When air cylinder is operating.
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RT=1 TH=2.2mm SXL=12+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)- (2)Air cylinder's adjustable range (3)Pump speed = aa (4)Pump speed = bb (5)Pump speed cc
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aa=1200r/min bb=275r/min cc=710r/min
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a=(7.5deg) b=(7.5deg)+-5deg c=(13deg)+-5deg d=5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=24.5deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Free (at shipping)
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aa=3.8-0.5mm
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a=10.5deg+-5deg b=56.5deg+7deg-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
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N1=325r/min Ra=5.5+-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)

Information:

Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Disconnect pressure line (3). Remove two bolts (2).2. Move fuel ratio control (1) up to disengage the fuel ratio control from the lever assembly in the governor. 3. Remove four O-ring seals (4) and screen assembly (5). The following steps are to install the fuel ratio control.4. Inspect, replace and install the four O-ring seals (4) and the screen assembly (5).5. Put the fuel ratio control (1) in position and engage the fuel ratio control with the lever assembly in the governor.6. Install the bolts that hold the fuel ratio control and connect pressure line (3) to the fuel ratio control (1). See Testing And Adjusting for Fuel Ratio Control Adjustment procedure.Disassemble And Assemble Fuel Ratio Control
Start By:a. remove fuel ratio control
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove the two bolts, and the fuel ratio control. Remove O-ring seal (1). 2. Put tooling (A) in a vise as shown so that the station being used is not over the vise jaw. Place the fuel ratio control over the pins in tooling (A). Remove cover (2) and the gasket.
There is spring force behind cover (3). Hold cover (3) in position, and slowly remove the bolts that hold it to release the spring force.
3. Remove cover (3). 4. Remove nut (5) and stop (6). 5. Remove spring (9), washer (7), and diaphragm (10) from retainer (8). Remove retainer (8) from housing (11). 6. Remove nut (16) from extension (15), and remove the extension from retainer (8). Remove valve (12), spring (13) and O-ring seal (14). 7. Remove spring (18), retainer (17) and spring (19). 8. Remove piston assembly (20). 9. Use tooling (B), and remove snap ring (21) and the wave washers from valve assembly (22). Remove piston assembly (23). Remove seal (24). 10. If necessary, remove stem (26) from valve (25).11. Clean and inspect all parts. Make a replacement of all parts that are worn or damaged. The following steps are to assemble the fuel ratio control.12. Assemble stem (26) to valve (25) using 9S3265 Retaining Compound.13. Put seal (24) on piston (23). Install piston (23) on valve assembly (22).14. Put two wave washers in position on valve (22). Use tooling (B) to install the snap ring on the valve assembly.15. Place housing (4) on tooling (A), and put tooling (C) into the bore of the housing. Lubricate tooling (C) with clean engine oil.16. Put a small amount of clean oil on the seal of the piston assembly, and push piston assembly (23) into position with a smooth swift motion.17. Place spring (9), retainer (17) and spring (19) in position in housing (4).18. Put O-ring seal (14) on extension (15). Put spring (13) and valve (12) in position on the extension.19. Lubricate O-ring seal (14) with clean engine oil. Install extension (15) in retainer (8). Install nut