107691-2421 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912421


107691-2421 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 107691-2421 1076912421

Cross reference number

ZEXEL 107691-2421 1076912421


Zexel num
Bosch num
Firm num
Name
107691-2421 
 
   
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.   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   1-5-3-6- 2-4
Pre-stroke mm   5.6 5.57 5.63
Beginning of injection position
Drive 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   10.4
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   87.5 85.9 89.1
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   2.25+-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   7.4+-0.5
Pump speed r/min   515 515 515
Average injection quantity mm3/st.   16 14.5 17.5
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(10.4)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   87.5 86.5 88.5
Basic   *
Fixing the lever   *
Boost pressure kPa   24.7 24.7
Boost pressure mmHg   185 185
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 5
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 5
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.4
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   98.5 94.5 102.5
Fixing the lever   *
Boost pressure kPa   24.7 24.7
Boost pressure mmHg   185 185
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 5
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 5
Boost compensator adjustment
Pump speed r/min   500 500 500
Rack position   R2-0.2
Boost pressure kPa   6.7 5.4 8
Boost pressure mmHg   50 40 60
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R2(R1-1. 15)
Boost pressure kPa   11.3 11.3 11.3
Boost pressure mmHg   85 85 85
Timer adjustment
Pump speed r/min   1070--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1020
Advance angle deg.   0 -0.5 0
Timer adjustment_03
Pump speed r/min   1080
Advance angle deg.   -1.3 -1.8 -0.8
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   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   5.6 5.57 5.63
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 107691-2421
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=L15 BCL=0.2+-0.1mm
----------

Speed control lever angle

Test data 107691-2421
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=26deg+-5deg b=(40deg)+-3deg

Stop lever angle

Test data 107691-2421
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)At speed = bb and rack position = cc, confirm that the stopper bolt is set at the non-injection position. (3)After setting the stopper bolt, confirm non-injection at speed dd.
----------
aa=40mm bb=1850r/min cc=1-0.5mm dd=340r/min
----------
a=15deg+-5deg b=(45deg)+-5deg

0000001301

Test data 107691-2421
(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=6deg bb=5.6+-0.03mm
----------
a=(8deg)

0000001401

Test data 107691-2421
(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 107691-2421
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107691-2421
C:Shim
----------

----------

0000001901

Test data 107691-2421
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 a counter clockwise direction when viewed from the drive side and adjust so that the adjustment point becomes the adjustment value, then fully tighten. 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 107691-2421
(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 RACK SENSOR

Test data 107691-2421
(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(10.4)+1.4mm
----------




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