107691-2251 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912251

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-2251 1076912251

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Cross reference number

ZEXEL 107691-2251 1076912251

Zexel num

Bosch num

Firm num

Name

107691-2251

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 R1-1.3

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 91 87 95

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

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=AC90
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)Use the hole at R = aa (3)Accelerator lever
----------
aa=38mm
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a=29deg+-5deg b=39.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Normal engine position (Rack position corresponding to bb) (3)Set the stopper bolt at rack position = cc and speed = dd and confirm non-injection
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aa=47mm bb=17.4mm cc=3.5+-0.3mm dd=0r/min
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a=4deg+-5deg b=(31deg) c=41deg+-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
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aa=5deg bb=5.6+-0.03mm
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a=(0deg)

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 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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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=1450r/min Ra=R1(12.5)+1.45mm
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0000002301 SPEED SENSOR

(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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Information:

Problem
The lift adjusting screw may break in certain 7E3969 1W5829, 4W8483, and 7W3710 Fuel Injection Nozzles with date codes of A9 thru M9, and A0 thru L0. If the adjusting screw breaks the adjustment screw in the nozzle can vibrate toward the fuel shutoff position which can result in the following symptoms:
A) Low Horsepower. The affected engine may not reach rated rpm. The engine does not emit any excessive black smoke. The engine may or may not have a detectable miss.B) Low Horsepower. The affected engine may not reach the rated rpm. The engine may emit heavy black smoke.C) Low Idle Misfire. Some engines run at rated speed but have a miss when idling.Affected Product
Model & Identification Number
3208 (30A3876-4565; 90N72172-73198; 75V10138-10420; 62W58913-Up; 01Z19535-22859; 03Z9391-10398; 51Z79496-80434)
Parts Needed
8* - 7E3969 Nozzle8* - 9L6969 Nozzle8* - 9N3299 Nozzle8* - 1W5829 Nozzle8* - 4W1819 Nozzle8* - 4W8483 Nozzle8* - 7W3710 Nozzle*Refer to your engine arrangement for the correct part number.Action Required
Parts Stock
Inspect all 7E3969, 9L6969, 9N3299, 1W5829, 4W1819, 4W8483, and 7W3710, Fuel Injection Nozzles for the date code as shown in the illustration. If date codes of A9, B9, C9, D9, E9, F9, G9, H9, I9, J9, K9, L9, M9, A0, B0, C0, D0, E0, F0, G0, H0, I0, J0, K0, or L0 are on the nozzles, remove the nozzles from parts stock.
Fuel Injection Nozzle Date Codes If the part number or date code is difficult to read, apply white paint to the area and carefully remove any excess.
Affected Product
If possible, isolate the cylinder(s) with a failed nozzle by loosening the fuel line nuts. The nozzle cap(s) may be removed to check for a broken lift adjustment screw.
Check the date code on the replacement nozzles before installing them. The date code on the flat of the nozzle nut must be M0, A1, B1, C1, or higher. Some nozzles will have a date code above the part number and a second date code on another flat of the nozzle nut. The second date code will continue two letters and a number. The first letter will always be an "R". The second letter is for the month "A-M". The number will be 0 for 1990 or 1 for 1991.
Any nozzle with a date code between A9 and M9 or A0 and L0 without the second date code should not be used.
On a twin engine marine installation, install new nozzles in both engines.
Service Claim Allowances
Parts Stock
Submit one claim for all 7E3969, 9L6969, 9N3299, 1W5829, 4W1819, 4W8483, and 7W3710, Fuel Injection Nozzles removed from parts stock.
Affected Product
This is a 5-hour job.
On a twin engine marine installation, a separate claim must be filed for the second engine.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.