107691-2490 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912490

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-2490 1076912490

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Service parts 107691-2490 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-1230

3. GOVERNOR 105921-8750

4. SUPPLY PUMP 105237-6070

5. AUTOM. ADVANCE MECHANIS 105681-1890

6. COUPLING PLATE 105663-0760

7. COUPLING PLATE

8. _ 159600-3521

9. _

10. NOZZLE AND HOLDER ASSY 105118-5381

11. Nozzle and Holder ME015202

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105048-3730

14. NOZZLE 105017-1221

15. NOZZLE SET

Include in #1:

107691-2490 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 107691-2490 1076912490

Zexel num

Bosch num

Firm num

Name

107691-2490

INJECTION-PUMP ASSEMBLY
14CG TICS MD-TI6 TICS

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 22.7 22.7

Boost pressure mmHg 170 170

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 22.7 22.7

Boost pressure mmHg 170 170

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 R2-0.15

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 9.3 9.3 9.3

Boost pressure mmHg 70 70 70

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

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=0.15+-0.1mm
----------

Speed control lever angle

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

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

(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

(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
----------

----------

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 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.
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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(10.4)+1.4mm
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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
----------

Information:

(1) 4N5906 Spring for valves (new): Length under test force ... 54.99 mm (2.165 in.)Test force ... 344 34 N (77 7.6 lb.)Use again minimum load at length under test force ... 291 N (65.4 lb.)Length of spring at valve open position ... 42.93 mm (1.690 in.)Use again minimum load at valve open position ... 817 N (183.6 lb.)Free length after test ... 62.7 mm (2.47 in.)Outside diameter ... 31.75 mm (1.250 in.)Spring must not be bent more than ... 2.18 mm (.086 in.)(2) Height to top of valve guide ... 32.3 0.8 mm (1.27 .03 in.)(3) Diameter of valve stem (new) ... 9.441 0.008 mm (.3717 .0003 in.) Use again minimum diameter of intake and exhaust valve stem ... 9.408 mm (.3704 in.)7N2271 Exhaust Valve - Do not use again.Bore in valve guide with guide installed in the head (new) ... 9.487 0.025 mm (.3735 .0010 in.)(4) Diameter of valve head: Exhaust valve ... 41.81 0.13 mm (1.646 .005 in.)Intake valve ... 44.98 0.13 mm (1.771 .005 in.)(5) Angle of intake valve face ... 29 1/4 1/4°Angle of exhaust valve face ... 44 1/4 1/4° (6) Depth of bore in head for valve seat insert (new) ... 13.01 0.38 mm (.512 .015 in.)(7) Diameter of valve seat insert for exhaust valve ... 42.850 0.013 mm (1.6870 .0005 in.) Bore in head for valve seat insert for exhaust valve ... 42.774 0.025 mm (1.6840 .0010 in.)(7) Diameter of valve seat insert for intake valve ... 46.025 0.013 mm (1.8120 .0005 in.) Bore in head for valve seat insert for intake valve ... 45.949 0.025 mm (1.8090 .0010 in.)(8) Angle of face of intake valve seat insert ... 30 1/4 1/2°Angle of face of exhaust valve seat insert ... 44 3/4 1/2°(9) Dimension from end of closed valve to machined face of head. Maximum permissible dimension:Below (recessed from) machined face ... 1.22 mm (.048 in.)Above (extended from) machined face ... 0.20 mm (.008 in.)(10) Outside diameter of the face of the valve seat insert: Exhaust seat ... 40.41 0.13 mm (1.591 .005 in.)Intake seat ... 44.04 0.13 mm (1.734 .005 in.)(11) "Use again" thickness of valve lip: Exhaust valve ... 2.03 mm (.080 in.)Intake valve ... 2.51 mm (.099 in.)