107691-2620 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912620


107691-2620 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 107691-2620 1076912620

Service parts 107691-2620 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 107069-0350
3. GOVERNOR 105956-0110
4. SUPPLY PUMP 105237-6130
5. AUTOM. ADVANCE MECHANIS 105681-5770
6. COUPLING PLATE 105663-0860
7. COUPLING PLATE
9. _
10. NOZZLE AND HOLDER ASSY 105160-4031
11. Nozzle and Holder ME075517
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105030-3550
14. NOZZLE 105025-2760
15. NOZZLE SET

Include in #1:

107691-2620 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 107691-2620 1076912620


Zexel num
Bosch num
Firm num
Name
107691-2620 
 
   
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
RED3 control unit part number   407910-3 960
RED3 rack sensor specifications mm   19
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   5.1 5.07 5.13
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
Rack position   (12.5)
Vist V   1.98 1.98 1.98
Pump speed r/min   800 800 800
Average injection quantity mm3/st.   140 139 141
Max. variation between cylinders %   0 -3 3
Basic   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
PS407910-303* V   1.75+-0. 01
PS407910-303* mm   3.1+-0.0 5
Injection quantity adjustment_02
Rack position   (6.6)
Vist V   2.9 2.8 3
Pump speed r/min   410 410 410
Average injection quantity mm3/st.   16.5 14.7 18.3
Max. variation between cylinders %   0 -15 15
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   5+-0.03
PS407910-303* V   V1-0.05+ -0.01
PS407910-303* mm   5+-0.03
Remarks
Refer to items regarding the pre-stroke actuator
 
Governor adjustment
Pump speed r/min   1050--
Advance angle deg.   0 0 0
Remarks
Start
 
Governor adjustment_02
Pump speed r/min   1000
Advance angle deg.   0 -0.5 0
Governor adjustment_03
Pump speed r/min   1075
Advance angle deg.   -1.5 -2 -1
Remarks
Finish
 
0000001201
CU407980-224*   *
Actuator retarding type   *
Supply voltage V   12 11.5 12.5
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   12 11.5 12.5
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   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 1.95 2.05
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   5.1 5.07 5.13
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:

Speed control lever angle

Test data 107691-2620
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=1mm bb=20mm
----------
a=39deg+-5deg b=37deg+-5deg

0000000901

Test data 107691-2620
(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=2deg bb=5.1+-0.03mm
----------
a=(2deg)

Stop lever angle

Test data 107691-2620
(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.
----------

----------

0000001301

Test data 107691-2620
A : Stopper pin B: Connector
----------

----------

0000001401

Test data 107691-2620
C:Shim
----------

----------

0000001501

Test data 107691-2620
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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0000001701

Test data 107691-2620
(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 19 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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0000001901 RACK SENSOR

Test data 107691-2620
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (154610-0620) (1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01. (2)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)
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V1=1.6V
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