107691-2350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912350

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-2350 1076912350

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Cross reference number

ZEXEL 107691-2350 1076912350

Zexel num

Bosch num

Firm num

Name

107691-2350

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)Accelerator lever (2)Use the hole at R = aa (3)Stopper bolt set position 'H'
----------
aa=38mm
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a=32deg+-5deg b=39.5deg+-3deg

Stop lever angle

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.
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aa=30mm bb=1+-0.3mm cc=0r/min
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a=35deg+-5deg b=45deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the timer to align with the pointer's groove. (4)Timer (5)Pointer (6)B.T.D.C.: aa (7)Pre-stroke: bb
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aa=5deg bb=5.6+-0.03mm
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a=(0deg) b=(37deg)

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)
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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.)
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L=0.8~1mm
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0000002401 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
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N1=275r/min Ra=8+-0.1mm
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Information:

This Program must be administered as soon as possible. When reporting the repair, use "PI3147" as the Part Number, "7751" as the Group Number, "56" as the Warranty Claim Description Code and "T" as the SIMS Description Code. Exception: If the repair is done after failure, use "PI3147" as the Part Number, "7751" as the Group Number, "96" as the Warranty Claim Description Code, and "Z" as the SIMS Description Code.
Refer to your Warranty Bulletin for detailed information with regard to Product Improvement Programs.
Completion Date
November 30, 1998Termination Date
November 30, 1998Problem
Certain 3116 and 3126 2-Valve Engines built from January 28 through February 6, 1998 with CBS heads are suspect to have improper installation of the brass injector sleeve.
Affected Product
Model & Identification Number
3116 (2WG6414-6426 5EN01269, 5EN1270, 5EN1273-1280, 5EN1282 4KG7773-7795 4KG31268NM3029-3043 9ZR771-774 )
Parts Needed
1 - 1192940 Gasket* - 1193061 Sleeve*(as required)Action Required
See the attached procedure.
Owner Notification
U.S. and Canadian owners will receive the attached Owner Notification.
Service Claim Allowances
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
MAKE EVERY EFFORT TO COMPLETE THIS PROGRAM AS SOON AS POSSIBLE.
Attach.(1-Owner Notification)(2-Rework Procedure)Copy Of Owner Notification For U.S. And Canadian Owners
Rework Procedure
1. Check to see if the head is supplied by CBS or Gosselies. The part number is located on the front of the head on the governor side beside the lifting eye, just above the front cover. In Marine applications, it is best viewed using a light to look between the expansion tank and heat exchanger.If it is a dot-matrix, then the head is from Gosselies. If the part number is stamped, then it is from CBS.
If the head is from Gosselies (dot-matrix part number), then the engine is good and no further work is needed.
If the head is from CBS (Stamped part number) then further inspection/rework is required.
2. If the head is from CBS, remove the valve cover.3. Using a sliding caliper, align the caliper vertically using the edge of the injector spring, measure and record the distance from the timing ledge on the injector to the top face of the head for each cylinder. This measurement will be in the range of 8.39 mm but can vary from engine to engine.4. If the variation from cylinder to cylinder on the same engine is less than 0.40 mm, then the engine is good. Re-install the valve cover. No further inspection is necessary.5. If the variation from cylinder to cylinder on the same engine is greater than 0.40 mm, recheck to verify measurements, if the difference is still greater than 0.40 mm, proceed to Step 6.6. Remove all (6) injectors. Using a depth gage with flat end and a 0.75 inch diameter steel ball dropped into the sleeve, check and record the distance from the top face of the head to the top of the steel ball. This measurement should be 2.583 0.18 inches (65.61 0.46 mm).7. Remove the injector sleeve on any cylinder that the measurement from step 6 is less than 2.565 inch (65.15 mm) and