107691-2381 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912381


107691-2381 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 107691-2381 1076912381

Service parts 107691-2381 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 107069-0171
3. GOVERNOR 105933-0451
4. SUPPLY PUMP 105237-6210
5. AUTOM. ADVANCE MECHANIS 105681-5420
6. COUPLING PLATE 105663-0840
7. COUPLING PLATE
9. _
10. NOZZLE AND HOLDER ASSY 105110-7360
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}
13. NOZZLE-HOLDER 105041-3110
14. NOZZLE
15. NOZZLE SET 105019-0340

Include in #1:

107691-2381 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 107691-2381 1076912381


Zexel num
Bosch num
Firm num
Name
107691-2381 
 
   
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   131424-8420
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   1-5-3-6- 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   12.5
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   105 103 107
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
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   465 465 465
Average injection quantity mm3/st.   14 12.2 15.8
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
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(12.5)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   105 104 106
Basic   *
Fixing the lever   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 5
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.45
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   102.5 98.5 106.5
Fixing the lever   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 5
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-1.4
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   90.5 86.5 94.5
Fixing the lever   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 5
Timer adjustment
Pump speed r/min   1250--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1200
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1470
Advance angle deg.   3 2.5 3.5
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   2.5 2.45 2.55
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   5.6 5.57 5.63
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 107691-2381
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=AD54
----------

Speed control lever angle

Test data 107691-2381
F:Full speed I:Idle (1)Accelerator lever (2)Use the hole at R = aa (3)Stopper bolt set position 'H'
----------
aa=38mm
----------
a=32deg+-5deg b=39.5deg+-3deg

Stop lever angle

Test data 107691-2381
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at rack position = bb, speed = cc and confirm non-injection.
----------
aa=30mm bb=1+-0.3mm cc=0r/min
----------
a=35deg+-5deg b=45deg+-5deg

0000001301

Test data 107691-2381
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the timer to align with the pointer's groove. (4)Timer (5)Pointer (6)B.T.D.C.: aa (7)Pre-stroke: bb
----------
aa=5deg bb=5.6+-0.03mm
----------
a=(0deg) b=(37deg)

0000001401

Test data 107691-2381
(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 107691-2381
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107691-2381
C:Shim
----------

----------

0000001901

Test data 107691-2381
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 RACK SENSOR

Test data 107691-2381
(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=1450r/min Ra=R1(12.5)+1.45mm
----------

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=275r/min Ra=8+-0.1mm
----------

0000002401 RACK SENSOR

Test data 107691-2381
V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------

0000002501 SPEED SENSOR

Test data 107691-2381
(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
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