107691-2271 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912271

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-2271 1076912271

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Cross reference number

ZEXEL 107691-2271 1076912271

Zexel num

Bosch num

Firm num

Name

107691-2271

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. 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 5.6 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 12.1

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 111.5 109.9 113.1

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 1.75+-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 7.5+-0.5

Pump speed r/min 520 520 520

Average injection quantity mm3/st. 10 8.2 11.8

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

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(12.1)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 111.5 110.5 112.5

Basic *

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.6+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+2.05

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 124.5 120.5 128.5

Fixing the lever *

Boost pressure kPa 32 32

Boost pressure mmHg 240 240

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.6+-0.0 5

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-1.2

Boost pressure kPa 5.3 4 6.6

Boost pressure mmHg 40 30 50

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-1. 2)

Boost pressure kPa 18.7 18.7 18.7

Boost pressure mmHg 140 140 140

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0 -0.5 0

Timer adjustment_03

Pump speed r/min 1075

Advance angle deg. -1.5 -2 -1

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 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 5.6 5.57 5.63

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:

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=AC37 BCL=1.2+-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=39deg+-5deg b=36deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
----------
aa=40mm bb=1300r/min cc=1.5+-0.3mm
----------
a=6deg+-5deg b=45deg+-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=8deg bb=5.6+-0.03mm
----------
a=(3deg)

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
----------

----------

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 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.)
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L=0.8~1mm
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0000002301 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=1300r/min Ra=R1(12.1)+2.05mm
----------

Information:

Parts Needed
6 - 6I2538 Clip Add injectors and related seals if clip is broken in more than three pieces. Add 336044 O-Ring Seal if thrust pad o-ring is damaged.
Action Required
Parts Stock
Remove all of the following injector groups from parts stock. Rework as described in the attached procedure and return to stock.
4P1410 Injector Group4P1420 Injector Group4P2810 Injector Group4P2820 Injector Group4P9510 Injector Group4P9520 Injector Group4P9610 Injector Group4P9620 Injector Group0R3177 Injector Group0R3178 Injector Group0R3400 Injector GroupAffected Product
Rework the injector groups as described in the attached procedure.
Service Claim Allowances
Parts Stock
Submit one claim for all injector groups removed from parts stock and reworked. List the labor to repair each injector on a separate labor line. A maximum of .2 hours labor per fuel injector will be allowed to remove and install the clip.
Affected Product
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach.
(1-Rework Procedure)Rework Procedure
Parts Stock or Off Engine
Illustration 1 - 9U5300 Unit Injector Spring Compressor Group
Illustration 2 - Compressor Group In Bench Vice
Illustration 3 - Use caution when handling injectors with missing clips. Loose springs and retainers will allow ball to come loose and fall into the engine.1. Remove injectors from packaging and inspect for a paint stripe across the top face of the spring retainer (either yellow or red). The paint stripe indicates the unit injector has been reworked previously. If a clip has failed and the spring/tappet/plunger are loose, use care during injector removal. The plunger retention ball (see Illustration 3) can drop out and fall into the cylinder/engine.
2. Install service tool in a bench vice as shown in Illustration 2 (position to allow for horizontal installation of injector).3. Use an o-ring pick to remove the o-ring from the injector spring retainer. Remove the rocker arm thrust pad.4. Install the injector in the 9U5300 Unit Injector Spring Compressor Group. Tighten the 5P0541 Nut to compress the spring enough to allow removal of the clip (the clip works like a valve keeper).5. Use a small magnet (pencil size works best) and a suitable clip removal tool to remove the oil clip from the injector. Do not release tension on the spring until a new clip is installed. Releasing tension before a new clip is installed will cause the injector will come apart.
6. Injectors removed from engines only. Inspect the clip that was removed. If the clip is broken in more than three (3) pieces (or if you suspect small pieces have fallen into the injector) the unit injector must be replaced.7. Install a new 6I2538 clip and remove injector from spring compressor group.8. Install thrust pad and thrust pad retaining o-ring. If the thrust pad retaining o-ring is damaged install a new 336044 O-Ring Seal.
9. Mark across the top face of the spring retainer with a yellow paint stripe.10. Repackage new parts and mark "3X" on the box.Affected Product
1. Check for 3X stamped on the block next to the serial number plate. If the block has been stamped do not proceed with the rework unless suspect injectors