107691-2034 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912034


107691-2034 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 107691-2034 1076912034

Cross reference number

ZEXEL 107691-2034 1076912034


Zexel num
Bosch num
Firm num
Name
107691-2034 
 
   
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   131425-0520
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.   407910-3 03*
Selector switch no.   03
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   16
Direction of rotation (viewed from drive side)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-5-3-6- 2-4
Pre-stroke mm   5.6 5.57 5.63
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cal 1-5
deg.   60 59.75 60.25
Difference between angles 2
Cal 1-3
deg.   120 119.75 120.25
Difference between angles 3
Cal 1-6
deg.   180 179.75 180.25
Difference between angles 4
Cyl.1-2
deg.   240 239.75 240.25
Difference between angles 5
Cal 1-4
deg.   300 299.75 300.25
Injection quantity adjustment
Adjusting point   -
Rack position   11.3
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   108 106.4 109.6
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 5
PS407910-303* V   1.75+-0. 01
PS407910-303* mm   3.6+-0.0 5
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   7.5+-0.5
Pump speed r/min   410 410 410
Average injection quantity mm3/st.   10 8.2 11.8
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   5.5+-0.0 3
PS407910-303* V   V1-0.05+ -0.01
PS407910-303* mm   5.5+-0.0 3
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(11.3)
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   108 107 109
Basic   *
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 5
PS407910-303* V   1.75+-0. 01
PS407910-303* mm   3.6+-0.0 5
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.8
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   119.5 115.5 123.5
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 5
PS407910-303* V   1.75+-0. 01
PS407910-303* mm   3.6+-0.0 5
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(R1-0. 6)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   107.5 103.5 111.5
Fixing the lever   *
Boost pressure kPa   36.7 36.7
Boost pressure mmHg   275 275
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 5
PS407910-303* V   1.75+-0. 01
PS407910-303* mm   3.6+-0.0 5
Boost compensator adjustment
Pump speed r/min   300 300 300
Rack position   R2-0.2
Boost pressure kPa   26 26 26
Boost pressure mmHg   195 195 195
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   R2(R1-0. 6)
Boost pressure kPa   28.7 27.4 30
Boost pressure mmHg   215 205 225
Timer adjustment
Pump speed r/min   1050--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1000
Advance angle deg.   0 -0.5 0
Timer adjustment_03
Pump speed r/min   1075
Advance angle deg.   -1.5 -2 -1
Remarks
Finish
 
0000001601
CU407980-224*   *
Actuator retarding type   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Pre-stroke mm   2.5 2.45 2.55
Output voltage V   2.83 2.82 2.84
Adjustment   *
_02
CU407980-224*   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Pre-stroke mm   5.6 5.57 5.63
Output voltage V   1.2 1 1.4
Confirmation   *
Remarks
Output voltage V1
 
_03
CU407980-224*   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Output voltage V   3.05 3.05
Confirmation of operating range   *
_04
CU407910-303*   *
Actuator retarding type   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Pre-stroke mm   2.5 2.45 2.55
Output voltage V   1.17 1.16 1.18
Adjustment   *
_05
CU407910-303*   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Pre-stroke mm   5.6 5.57 5.63
Output voltage V   2.8 2.6 3
Confirmation   *
Remarks
Output voltage V1
 
_06
CU407910-303*   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Output voltage V   0.95
Confirmation of operating range   *

Test data Ex:

Governor adjustment

Test data 107691-2034
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=AG95 BCL=0.2+-0.1mm
----------

Speed control lever angle

Test data 107691-2034
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=39deg+-5deg b=35.5deg+-3deg

Stop lever angle

Test data 107691-2034
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=1300r/min cc=1.5+-0.3mm
----------
a=6deg+-5deg b=45deg+-5deg

0000001301

Test data 107691-2034
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=8deg bb=5.6+-0.03mm
----------
a=(3deg)

0000001401

Test data 107691-2034
(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.
----------

----------

0000001701

Test data 107691-2034
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107691-2034
C:Shim
----------

----------

0000001901

Test data 107691-2034
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.
----------

----------

0000002201 SPEED SENSOR

Test data 107691-2034
(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------

0000002301 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=8.5+-0.1mm
----------

0000002401 RACK SENSOR

Test data 107691-2034
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1300r/min Ra=R1(11.3)+1.8mm
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