107491-3180 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1074913180


107491-3180 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 107491-3180 1074913180

Cross reference number

ZEXEL 107491-3180 1074913180


Zexel num
Bosch num
Firm num
Name
107491-3180 
 
   
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   105780-8250
Bosch type code   1 688 901 101
Nozzle   105780-0120
Bosch type code   1 688 901 990
Nozzle holder   105780-2190
Opening pressure MPa   20.7
Opening pressure kgf/cm2   211
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   8-3-600
Overflow valve   131425-0920
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   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   17
Direction of rotation (viewed from drive side)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-3-4-2
Pre-stroke mm   5.1 5.07 5.13
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-3
deg.   90 89.75 90.25
Difference between angles 2
Cal 1-4
deg.   180 179.75 180.25
Difference between angles 3
Cyl.1-2
deg.   270 269.75 270.25
Injection quantity adjustment
Adjusting point   -
Rack position   12.6
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   118 115 121
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the rack   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   8+-0.5
Pump speed r/min   505 505 505
Each cylinder's injection qty mm3/st.   11.5 10.35 12.65
Fixing the rack   *
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   5+-0.03
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Refer to items regarding the pre-stroke actuator
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.6)
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   118 116 120
Basic   *
Fixing the lever   *
Boost pressure kPa   44 44
Boost pressure mmHg   330 330
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+2.15
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   130 124 136
Fixing the lever   *
Boost pressure kPa   44 44
Boost pressure mmHg   330 330
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2-(0.55 )
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   102.5 99.5 105.5
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
Boost compensator adjustment
Pump speed r/min   400 400 400
Rack position   R2-(0.55 )
Boost pressure kPa   22 20.7 23.3
Boost pressure mmHg   165 155 175
Boost compensator adjustment_02
Pump speed r/min   400 400 400
Rack position   R2(R1-0. 95)
Boost pressure kPa   30.7 30.7 30.7
Boost pressure mmHg   230 230 230
Timer adjustment
Pump speed r/min   1170--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1120
Advance angle deg.   0 -0.3 0
Timer adjustment_03
Pump speed r/min   1250-50
Advance angle deg.   -1.5 -1.8 -1.2
Remarks
Finish
 
0000001601
CU407980-224*   *
Actuator retarding type   *
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   2 1.95 2.05
Output voltage V   2.83 2.82 2.84
Adjustment   *
_02
CU407980-224*   *
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   5.1 5.07 5.13
Output voltage V   1.2 1 1.4
Confirmation   *
Remarks
Output voltage V1
 
_03
CU407980-224*   *
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Output voltage V   3.05 3.05
Confirmation of operating range   *

Test data Ex:

Governor adjustment

Test data 107491-3180
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=AF54 BCL=(0.55)+-0.1mm
----------

Speed control lever angle

Test data 107491-3180
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=5deg+-5deg b=34.5deg+-3deg

Stop lever angle

Test data 107491-3180
N:Pump normal S:Stop the pump. (1)Position at the normal side lever position (back off the stop screw and move fully to the normal side). Next, screw in the stop screw and set where it contacts the stop lever. (2)Use the hole at R = aa
----------
aa=35mm
----------
a=10.5deg+-5deg b=40deg+-5deg

0000001301

Test data 107491-3180
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=5.1+-0.03mm
----------
a=(20deg)

0000001401

Test data 107491-3180
(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
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0000001701

Test data 107491-3180
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107491-3180
C:Shim
----------

----------

0000001901

Test data 107491-3180
A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully clockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the counterclockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
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0000002201 RACK SENSOR

Test data 107491-3180
G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
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Ra=R1(12.6)+2.15mm N1=1250r/min V1=3+-0.01V
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