107691-2880 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076912880

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-2880 1076912880

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Service parts 107691-2880 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-1340

3. GOVERNOR 105956-0143

4. SUPPLY PUMP 105237-6070

5. AUTOM. ADVANCE MECHANIS 105681-2430

6. COUPLING PLATE 105663-0760

7. COUPLING PLATE

8. _ 159601-6320

9. _

10. NOZZLE AND HOLDER ASSY 105118-6550

11. Nozzle and Holder ME086835

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

13. NOZZLE-HOLDER 105048-3730

14. NOZZLE 105017-2290

15. NOZZLE SET

Include in #1:

107691-2880 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 107691-2880 1076912880

Zexel num

Bosch num

Firm num

Name

107691-2880

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

RED3 control unit part number 407910-3 960

RED3 rack sensor specifications mm 19

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 14

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 5.1 5.07 5.13

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

Rack position (9.7)

Vist V 2.39 2.39 2.39

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 96 95 97

Max. variation between cylinders % 0 -3 3

Basic *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Injection quantity adjustment_02

Rack position (6.5)

Vist V 2.9 2.8 3

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 16 14.5 17.5

Max. variation between cylinders % 0 -15 15

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5+-0.03

Remarks
Refer to items regarding the pre-stroke actuator

Governor adjustment

Pump speed r/min -

Advance angle deg. 0 -0.5 0

Remarks
Measure the actual speed.

Governor adjustment_02

Pump speed r/min -

Advance angle deg. -1.3 -1.8 -0.8

Remarks
Measure the actual speed, stop

0000001201

CU407980-224* *

Actuator retarding type *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2 1.95 2.05

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 5.1 5.07 5.13

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:

Speed control lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
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aa=1mm bb=20mm
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a=39.5deg+-5deg b=37deg+-5deg

0000000901

(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=6deg bb=5.1+-0.03mm
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a=(7deg)

Stop lever angle

(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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0000001301

A : Stopper pin B: Connector
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0000001401

C:Shim
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0000001501

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 counterclockwise (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 clockwise 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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0000001701

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 19 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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0000001901 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 (154610-0620) (1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01. (2)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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V1=1.6V
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Information:

3. Remove connecting rod caps (1) from the two connecting rods and push the pistons up until the rings are free of the cylinder liner.4. Remove the two pistons.5. Do the above steps again for the remainder of the pistons.Install Pistons
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and connecting rod bearings.3. Move the piston rings on the piston until the ring openings (gap) are approximately 180° apart.
Never install tool (A) (the ring compressor) without the use of the cylinder liner as a guide. Damage to the piston rings can be the result.
TYPICAL EXAMPLE4. Put tool (A) in position on the cylinder liner as shown. Put the connecting rod and piston in position in the same cylinder liner from which it was removed and into the ring compressor. Make sure the "V" mark on the piston is in alignment with the "V" mark on the cylinder block.5. Push the piston into position while the connecting rod is put into position over the crankshaft. 6. Put clean engine oil on bearings, bolt threads and surfaces of the nuts that make contact with the connecting rod caps. Put caps (1) in position on the connecting rods and install the nuts. Tighten the nuts to a torque of 30 3 lb.ft. (40 4 N m). Put a mark on each nut and the end of each bolt. Tighten the nuts 90° more.
When the connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
7. Follow Steps 1 through 6 for the installation of the other pistons.end by:a) install oil pumpb) install cylinder head assemblyDisassemble And Assemble Pistons
start by:a) remove pistons 1. Remove keystone rings from the piston with tool (A). 2. Remove snap ring (3), piston pin (1) and connecting rod (2) from the piston.3. Clean the piston ring grooves on the old piston with an acceptable ring groove tool. For clearances on pistons and rings of earlier models, see PISTON AND RINGS in SPECIFICATIONS.4. See SPECIAL INSTRUCTIONS, Form SMHS7295 for USE OF PISTON PIN REMOVAL AND INSTALLATION TOOLS. Be sure to remove the bearings from the crankshaft end of connecting rod.5. Heat the connecting rod in an oven to a temperature of 350°-500°F (176°-260°C). Never use a direct flame to heat a connecting rod. 6. Put the connecting rod in position on tooling (B) for the regular rod. Use tooling (C) for the tapered rod. Put a new rod pin bearing in position. Make sure the rod pin bearing joint (4) is 90° from a center line through crankshaft and pin bearing bores.7. Remove the old rod pin bearing and install the new rod pin bearing with one operation. 8. Use a pin bearing machine