107692-5122 ZEXEL Calibration Data 1076925122

Information Cross number Calibration Data Calibration Data Ex

Information

ZEXEL 107692-5122 1076925122

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Cross reference number

ZEXEL 107692-5122 1076925122

Zexel num

Bosch num

Firm num

Name

107692-5122

FE6TA

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 1-4-2-6- 3-5

Pre-stroke mm 5.1 5.07 5.13

Beginning of injection position
Drive 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 14.7

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 110.5 108.5 112.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.1+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8.4+-0.5

Pump speed r/min 545 545 545

Average injection quantity mm3/st. 22.5 20.7 24.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5+-0.03

PS407910-303* V V1+0.05+ -0.01

PS407910-303* 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(14.7)

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 110.5 109.5 111.5

Basic *

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.1+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1-2.05

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 101.5 97.5 105.5

Fixing the lever *

Boost pressure kPa 28 28

Boost pressure mmHg 210 210

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.1+-0.0 5

Injection quantity adjustment_05

Adjusting point C

Rack position (R2-0.7)

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 47.7 45.7 49.7

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

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 350 350 350

Rack position (R2-0.7)

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 350 350 350

Rack position R2(R1-3. 95)

Boost pressure kPa 14.7 14.7 14.7

Boost pressure mmHg 110 110 110

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

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 12 11.5 12.5

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 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 1.95 2.05

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 5.1 5.07 5.13

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=AF93 BCL=(0.7)mm
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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=93.5mm
----------
a=17deg+-5deg b=(37deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt at rack position = bb (non-injection rack position), (speed = cc)
----------
aa=37mm bb=1.5+-0.3mm cc=0r/min
----------
a=20deg+-5deg b=45deg+-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)-
----------
aa=5.1+-0.03mm
----------
a=(20deg)

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 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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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=1300r/min Ra=R1(14.7)mm
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Information:

For all marine transmission lubrication and maintenance activities, refer to your marine transmission or vessel OEM literature.Use fuel consumption, service hours, or calendar time, whichever occurs first, to determine maintenance intervals. Experience has shown that maintenance intervals are most accurately scheduled on the basis of fuel consumed rather than service hours.Daily
Walk-Around Inspection - Inspect engine for leaks and loose connections Engine Crankcase - Check oil level Cooling System - Check coolant level Air Cleaner - Check service indicator/Service air cleaner when needed Air Starter (If Equipped) - Check lubricator oil level Clutch (If Equipped) - Check/Adjust/Lubricate Marine Transmission - Check oil levelEvery 2550 L (675 gal) of Fuel or 50 Hours
Zinc Rods - Inspect/ReplaceFirst 12,750 L (3375 gal) of Fuel or 250 Hours
1 Valve Lash - Check/Adjust (at the first oil change interval)Every 12,750 L (3375 gal) of Fuel or 250 Hours or Yearly
1 Scheduled Oil Sampling (S O S) - Obtain Sample and analysis1 Engine Crankcase - Replace oil and filter(s)1 Crankcase Breathers - Clean Fuel System - Clean primary fuel filter (if equipped)/Replace final fuel filter Fuel Tank - Drain water and sediment Cooling System (Conventional HD Coolant Only) - Test for SCA concentration OR obtain Level I coolant analysis/Add SCA if necessary Air Cleaner - Clean/Replace air filter elements Belts - Check/Adjust/Replace Hoses and Clamps - Inspect/Replace Batteries - Clean/Check (if required)Every 51,000 L (13,500 gal) Of Fuel Or 1000 Hours
Engine Protection Devices - Inspect/Check Magnetic Pickup - Inspect/AdjustEvery 153,500 L (40,500 gal) Of Fuel Or 3000 Hours
Water Temperature Regulators (Thermostats) - Replace Cooling System (Extended Life Coolant Only) - Add Extender2 Cooling System (Conventional HD Coolant Only) - Drain/Clean/Replace coolant Engine Mounts - Inspect Crankshaft Vibration Damper - Inspect Valve Lash, Valve Rotators - Check/Adjust Fuel Ratio Control, Set Point, and Low Idle - Check/Adjust PAR Analysis - ObtainEvery 256,000 L (67,500 gal) Of Fuel Or 5000 Hours
Fuel Injection Nozzles - Test/Exchange Jacket Water Pump - Inspect/Rebuild or Exchange Raw/Sea Water Pump - Inspect/Rebuild or Exchange Alternator - Inspect/Rebuild or Exchange Starting Motor - Inspect/Rebuild or Exchange Air Compressor (If Equipped) - Inspect/Rebuild or Exchange Turbocharger - Clean/Inspect/CheckEvery 6000 Hours Or Four Years
Cooling System (Extended Life Coolant Only) - Drain/Flush/Replace CoolantOverhaul
Overhaul Considerations13408 Marine Engines that are equipped with the deep oil sump [87 L (92 qt)] may perform this maintenance after 25,500 L (6750 gal) of fuel or 500 Hours.2If a commercial HD coolant/antifreeze meeting ASTM D4985 specifications is used, or if a mixture of commercial SCA and water is used, this maintenance should be performed at a maximum of One Year.