107691-3440 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076913440

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107691-3440 1076913440

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Cross reference number

ZEXEL 107691-3440 1076913440

Zexel num

Bosch num

Firm num

Name

107691-3440

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 131425-0920

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 1-4-2-6- 3-5

Pre-stroke mm 5.1 5.07 5.13

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 12.4

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 116 113 119

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-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 440 440 440

Each cylinder's injection qty mm3/st. 13.5 12.5 14.5

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5+-0.03

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(12.4)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 116 114 118

Basic *

Fixing the lever *

Boost pressure kPa 57.3 57.3

Boost pressure mmHg 430 430

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+2.15

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 129 123 135

Fixing the lever *

Boost pressure kPa 57.3 57.3

Boost pressure mmHg 430 430

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Injection quantity adjustment_05

Adjusting point C

Rack position (R2-0.6)

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 91 88 94

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position (R2-0.6)

Boost pressure kPa 24.7 23.4 26

Boost pressure mmHg 185 175 195

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2[R1-1]

Boost pressure kPa 44 44 44

Boost pressure mmHg 330 330 330

Timer adjustment

Pump speed r/min 0

Advance angle deg. 0 0 0

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0 0 0

Remarks
Measure speed (beginning of operation).

Timer adjustment_03

Pump speed r/min -

Advance angle deg. -1.5 -1.8 -1.2

Remarks
Measure the actual speed, stop

0000001601

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:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Stop lever's normal position setting: RA (4)Boost compensator stroke: BCL (5)When setting the stop lever after governor adjustment, confirm that rack position Ra (point B) can be obtained at full setting.
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T1=AF50 RA=(18)mm BCL=(0.6)+-0.1mm Ra=R1(12.4)+2.15mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=39.5mm
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a=32deg+-5deg b=34deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, stopper bolt setting (2)Speed = bb, rack position = cc (3)Use the hole above R = dd
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aa=(18)mm bb=0r/min cc=1.5+-0.1mm dd=28mm
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a=15deg+-5deg b=35deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
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aa=5.1+-0.03mm
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a=(80deg)

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=1250r/min Ra=R1(12.4)+2.15mm
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0000002301 AIR CYLINDER

1. Air cylinder adjustment procedure (1)Set the speed lever at idle. (2)Temporarily set the clearance between the air cylinder (C) and the set bolt (B) to L1. (3)Set the speed at N. (4)Apply positive pressure P1 to the air cylinder (C). (5)Gradually push out the set bolt (B). (6)Tighten the nut (D) at the point where the rack position is Ra at speed N. (7)Apply positive pressure P1 several times. (8)Confirm that the lever returns to the idle position at positive pressure P2.
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L=(6)mm N=335r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2) Ra=8+-0.1mm
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0000002401 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Lever 1. Aneroid compensator unit adjustment (1)Screw in (A) to obtain L1. (2)Select C so that dimension L2 can be obtained. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Set to full boost. (3)Screw in the aneroid compensator body to obtain the performance shown in the graph above. (4)As there is hysterisis, measure when the absolute pressure drops. (5)Hysterisis must not exceed rack position = h1.
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N1=1250r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
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Ra=R3[R1+2.15]mm Rb=R3-0.75mm Rc=(R3-0.9)mm P1=(89.8)+-2.7kPa((674)+-20mmHg) P2=70.1+-0.7kPa(526+-5mmHg) P3=65.7+-1.3kPa(493+-10mmHg) Q1=(129)+-3cm3/1000st Q2=(118)cm3/1000st Q3=(113)cm3/1000st

Information:

start by: a) remove flywheel When a replacement of the rear seal is made, a replacement of the wear sleeve is to be made also. 1. Remove the crankshaft rear seal from the flywheel housing with tooling (A).2. Install tool (C) in the rear seal bore. 3. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.4. Remove tool (C) and the wear sleeve by hand.Install Crankshaft Rear Seal And Wear Sleeve
The crankshaft seal and wear sleeve come as a set and must not be separated from each other at any time. Carefully read Special Instruction, Form No. SMHS8508, that is included with each seal and wear sleeve before any handling of the seal group is made.
1. Install the crankshaft rear seal and wear sleeve with tooling (A) as follows: a) Clean and make a preparation of the crankshaft outside diameter with 6V1541 Quick Cure Primer. Make an application of 9S3265 Retaining Compound to crankshaft outside diameter.b) Install locator (3) and the bolts on the rear of the crankshaft (4).c) Put the wear sleeve (2) and seal (7) as a unit on locator (3) with the outside diameter bevel of the wear sleeve toward the outside.d) Put installer (5) in position on the locator (3).e) Put clean engine oil on the face of nut (6) and install it on the locator. Tighten the nut until installer (5) is at bottom.f) Remove tooling (A) and check the wear sleeve and seal for the correct position after installation.end by: a) install flywheel