107691-3094 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076913094

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Information injection-pump assembly

ZEXEL 107691-3094 1076913094

Cross reference number

ZEXEL 107691-3094 1076913094

Zexel num

Bosch num

Firm num

Name

107691-3094

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 131424-9720

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. 01

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 15

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 5.1 5.07 5.13

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 11.3

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 123 121 125

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.1+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 6+-0.5

Pump speed r/min 440 440 440

Average injection quantity mm3/st. 21 20 22

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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

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 750 750 750

Average injection quantity mm3/st. 123 122 124

Basic *

Fixing the lever *

Boost pressure kPa 88 88

Boost pressure mmHg 660 660

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.1+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+2.25

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 129.5 123.5 135.5

Fixing the lever *

Boost pressure kPa 88 88

Boost pressure mmHg 660 660

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.1+-0.0 5

Injection quantity adjustment_05

Adjusting point C

Rack position (R2-2.95 )

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 74.5 72.5 76.5

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

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position (R2-2.95 )

Boost pressure kPa 18.7 17.4 20

Boost pressure mmHg 140 130 150

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2(R1-0. 35)

Boost pressure kPa 74.6 74.6 74.6

Boost pressure mmHg 560 560 560

Timer adjustment

Pump speed r/min 1180--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1130

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 advancing 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 advancing 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 *

_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 1.2 1 1.4

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 3.05 3.05

Confirmation of operating range *

Test data Ex:

Governor adjustment

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=AB78 BCL=(2.95)+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=(40.5deg)+-3deg b=42deg+-5deg

Stop lever angle

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)Set the stopper bolt so that speed = aa and rack position = bb (Confirm non-injection at speed = cc). (3)Use the hole above R = dd
----------
aa=0r/min bb=1+-0.1mm cc=1465r/min dd=30mm
----------
a=34.5deg+-5deg b=46deg+-5deg

0000001301

(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=4deg bb=5.1+-0.03mm
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a=(50deg)

0000001401

(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

A : Stopper pin B: Connector
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----------

0000001801

C:Shim
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0000001901

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 counterclockwise (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 clockwise 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

(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=1250r/min Ra=R1(12.3)+2.25mm
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0000002301 TAMPER PROOF

SW:Inner hexagonal SW14 (F): Apply thread lock adhesive . (G): Full tamper proof (H): Full boost (Full rack) (I): 0 boost 1. Mount (C) and (D) after adjusting the boost compensator. 2. Back off the load lever set screw L1 from the end face of the governor housing.. 3. Apply boost pressure and set the full load at tamper set position point aa to obtain N1, Q1 and Ra using the screw C. 4. Fix using the nut (D). 5. Next, after adjusting the stop lever, confirm the point aa. 6. Reset the load lever to the full boost rack. 7. After completion of setting, seal using the plug (E).
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L1=6+1mm N1=1250r/min Ra=(R1+3.25)+-0.1mm Q1=- aa=D
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T1 T=53.9~73.5N-m(5.5~7.5Kgf-m) T2 T=2.94~4.41N-m(0.3~0.45Kgf-m)

0000002401 TAMPER PROOF

(A): Rotation tamper proof (B): Full-speed setting 1. Back off the full-speed set bolt. 2. Confirm that the tamper setting position is N1, R1, Q1. 3. At that time, record the angle of the speed lever. 4. After confirming the above setting, set full speed.
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N1=1430r/min R1=(12.3)+2-1mm Q1=-
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T1 T=53.9~73.5N-m(5.5~7.5Kgf-m) T2 T=2.94~4.41N-m(0.3~0.45Kgf-m)