107692-1090 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076921090 8943944330


107692-1090 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 107692-1090 1076921090
ISUZU 8943944330 8943944330

Cross reference number

ZEXEL 107692-1090 1076921090
ISUZU 8943944330 8943944330


Zexel num
Bosch num
Firm num
Name
107692-1090 
107692-1091 
 
8943944330  ISUZU
INJECTION-PUMP ASSEMBLY
6HE1-XS * K

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8140
Bosch type code   EF8511/9A
Nozzle   105780-0000
Bosch type code   DN12SD12T
Nozzle holder   105780-2080
Bosch type code   EF8511/9
Opening pressure MPa   17.2
Opening pressure kgf/cm2   175
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.   00
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   11
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   1.9 1.87 1.93
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   13.8
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   120 118.4 121.6
Max. variation between cylinders %   0 -2.5 2.5
Basic   *
Fixing the rack   *
PS407980-224* V   1.88+-0. 01
PS407980-224* mm   3.2+-0.0 3
PS407910-303* V   1.88+-0. 01
PS407910-303* mm   3.2+-0.0 3
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   8.5+-0.5
Pump speed r/min   570 570 570
Average injection quantity mm3/st.   12.5 11.2 13.8
Max. variation between cylinders %   0 -14 14
Fixing the rack   *
PS407980-224* V   1.88+-0. 01
PS407980-224* mm   3.2+-0.0 3
PS407910-303* V   1.88+-0. 01
PS407910-303* mm   3.2+-0.0 3
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(13.8)
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   120 119 121
Basic   *
Fixing the lever   *
Boost pressure kPa   62.7 62.7
Boost pressure mmHg   470 470
PS407980-224* V   1.88+-0. 01
PS407980-224* mm   3.2+-0.0 3
PS407910-303* V   1.88+-0. 01
PS407910-303* mm   3.2+-0.0 3
Boost compensator adjustment
Pump speed r/min   300 300 300
Rack position   R2-2.75
Boost pressure kPa   17.3 16 18.6
Boost pressure mmHg   130 120 140
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   R2(R1-0. 5)
Boost pressure kPa   49.3 49.3 49.3
Boost pressure mmHg   370 370 370
0000001601
CU407980-224*   *
Actuator advancing type   *
Supply voltage V   12 11.5 12.5
Ambient temperature degC   23 18 28
Pre-stroke mm   5 4.95 5.05
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   1.9 1.87 1.93
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   5 4.95 5.05
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   1.9 1.87 1.93
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

Test data 107692-1090
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=AA11 BCL=2.75+-0.1mm
----------

Speed control lever angle

Test data 107692-1090
F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=0deg+-5deg b=(39deg)+-3deg

Stop lever angle

Test data 107692-1090
N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection.
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=12deg+-5deg b=44deg+-5deg

0000001301

Test data 107692-1090
(1)Pump vertical direction (2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=19deg bb=1.9+-0.03mm
----------
a=(60deg)

0000001401

Test data 107692-1090
(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 107692-1090
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107692-1090
C:Shim
----------

----------

0000001901

Test data 107692-1090
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 107692-1090
(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(13.8)+2.8mm
----------

0000002301 ACS

Test data 107692-1090
(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Lever 1. Aneroid compensator unit adjustment (1)Screw in (A) to obtain L1. (2)Select C so that dimension L2 can be obtained. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Set to full boost. (3)Screw in the aneroid compensator body to obtain the performance shown in the graph above. (4)As there is hysterisis, measure when the absolute pressure drops. (5)Hysterisis must not exceed rack position = h1.
----------
N1=1250r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3(R1+2.8)mm Rb=R3-0.15mm Rc=R3-0.6mm P1=(89.9)+-2.7kPa((674)+-20mmHg) P2=78.4+-2.7kPa(588+-20mmHg) P3=58.7+-0.7kPa(440+-5mmHg) Q1=(144)cm3/1000st Q2=(142)cm3/1000st Q3=(136)cm3/1000st

0000002401 ACS

Test data 107692-1090
(A) Negative pressure inlet (B) Screw (C) Boost pressure inlet (D) aneroid compensator body (E) rack position aligning screw (F) aneroid compensator spring (G) boost compensator spring (H) end of cover boss (I) spring setting adjusting notch (J) top face of lever (K) push rod 1. Aneroid and boost compensator adjustment method (1)When adjusting the boost compensator, remove the aneroid compensator. (2)At full boost, select a pushrod so that the stroke is L2. (3)Turn screw (E) and adjust the boost compensator stroke. (4)Adjust the beginning of boost compensator operation using the notch (I). (5)Set aneroid compensator at full boost. (6)Turn screw (B) to adjust the clearance between the snapring and body to L1. (7)Screw in the aneroid compensator body to adjust the beginning of aneroid compensator operation.
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L1=1.5+-0.5mm L2=37.5+-0.5mm
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107692-1090  

107692-1091 
 
8943944330 
INJECTION-PUMP ASSEMBLY
6HE1-XS
F 019 Z10 461 
8943944331 
INJECTION-PUMP ASSEMBLY
6HE1-XS
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