Information injection-pump assembly
ZEXEL
107492-2064
1074922064
Rating:
Service parts 107492-2064 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
ME015202
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107492-2064
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
107492-2064
1074922064
Zexel num
Bosch num
Firm num
Name
107492-2064
INJECTION-PUMP ASSEMBLY
14CF TICS MD-TI4 TICS
14CF TICS MD-TI4 TICS
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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.
02
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
01
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
5.6
5.57
5.63
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
Cyl.1-2 deg. 270 269.75 270.25
Injection quantity adjustment
Adjusting point
-
Rack position
12.8
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
101
99.4
102.6
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
8.4+-0.5
Pump speed
r/min
540
540
540
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
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.8)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
101
100
102
Basic
*
Fixing the lever
*
Boost pressure
kPa
42
42
Boost pressure
mmHg
315
315
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+1.55
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
99
95
103
Fixing the lever
*
Boost pressure
kPa
42
42
Boost pressure
mmHg
315
315
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
300
300
300
Rack position
R2-0.75
Boost pressure
kPa
22
20.7
23.3
Boost pressure
mmHg
165
155
175
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2[R1-0.
95]
Boost pressure
kPa
28.7
28.7
28.7
Boost pressure
mmHg
215
215
215
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
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
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=K79 BCL=0.75+-0.1mm
----------
----------
T1=K79 BCL=0.75+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=22deg+-5deg b=(38deg)+-3deg
----------
----------
a=22deg+-5deg b=(38deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection.
(2)After setting the stopper bolt, confirm non-injection at speed cc.
----------
aa=1450r/min bb=6.2-0.5mm cc=300r/min
----------
a=36.5deg+-5deg b=(33deg)+-5deg
----------
aa=1450r/min bb=6.2-0.5mm cc=300r/min
----------
a=36.5deg+-5deg b=(33deg)+-5deg
0000001301
(1)Pump vertical direction
(2)Position of gear mark '3' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)Pre-stroke: bb
----------
aa=7deg bb=5.6+-0.03mm
----------
a=(130deg)
----------
aa=7deg bb=5.6+-0.03mm
----------
a=(130deg)
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.
----------
----------
----------
----------
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 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.
----------
----------
----------
----------
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=1500r/min Ra=R1(12.8)+1.55mm
----------
----------
N1=1500r/min Ra=R1(12.8)+1.55mm
----------
Information:
The electrical system is a combination of two separate electric circuits: the charging circuit and starting circuit. Each circuit is dependent on some of the same components. The battery (batteries), disconnect switch, circuit breaker, ammeter, cables and wires from the battery are common in each of the circuits.
The disconnect switch must be ON to allow the electrical system to function. Some charging circuit components will be damaged if the engine is operated with the disconnect switch OFF.
The charging circuit is in operation when the diesel engine is operating. The electricity producing (charging) unit is an alternator. An alternator regulator in the circuit senses the state of charge in the battery and regulates the alternator output to keep the battery fully charged.The starting circuit operates only when the disconnect switch is ON and the start switch is actuated.The direct electric diesel engine starting circuit includes a glow plug for each diesel engine cylinder. Glow plugs are small heating elements in the precombustion chambers which promote fuel ignition when the engine is started in low temperatures.The lighting and charging circuits are both connected on the same side of the ammeter while the starting circuit connects to the other side of the ammeter. This alternator is a three phase self-rectifying charging unit.The alternator has four main components: end frame assembly (brush end), rotor assembly, stator and shell assembly, and end frame assembly (drive end).A separate regulator senses the charge condition of the battery as well as electrical system power demand and controls the alternator output accordingly by limiting the field current.
Never operate the alternator without the battery in the circuit. Making or breaking an alternator connection with a heavy load on the circuit will sometimes result in regulator damage.
The starting motor is a device used to rotate the flywheel of an engine fast enough to start the engine. Alternator Charging Circuit
(Negative Ground System Illustrated)
24 VOLT DIRECT ELECTRIC STARTING MOTORThe starting motor used with direct electric start incorporates a solenoid. The action of the solenoid engages the pinion with the ring gear on the engine flywheel, when the solenoid is energized. The pinion always engages before the electric contacts in the solenoid closes the circuit between the battery and the starting motor. An over-running clutch protects the starting motor from being overspeeded. Releasing the start-switch disengages the pinion from the ring gear on the flywheel.A solenoid is a magnetic switch that utilizes low current to close a high current circuit. The solenoid has an electromagnet with a movable core. There are contacts on the end of the core. The contacts are held open by a spring that pushes the core away from the magnetic center of the coil. Low current will energize the coil and form a magnetic field. The magnetic field draws the core to the center of the coil and the contacts close.
The disconnect switch must be ON to allow the electrical system to function. Some charging circuit components will be damaged if the engine is operated with the disconnect switch OFF.
The charging circuit is in operation when the diesel engine is operating. The electricity producing (charging) unit is an alternator. An alternator regulator in the circuit senses the state of charge in the battery and regulates the alternator output to keep the battery fully charged.The starting circuit operates only when the disconnect switch is ON and the start switch is actuated.The direct electric diesel engine starting circuit includes a glow plug for each diesel engine cylinder. Glow plugs are small heating elements in the precombustion chambers which promote fuel ignition when the engine is started in low temperatures.The lighting and charging circuits are both connected on the same side of the ammeter while the starting circuit connects to the other side of the ammeter. This alternator is a three phase self-rectifying charging unit.The alternator has four main components: end frame assembly (brush end), rotor assembly, stator and shell assembly, and end frame assembly (drive end).A separate regulator senses the charge condition of the battery as well as electrical system power demand and controls the alternator output accordingly by limiting the field current.
Never operate the alternator without the battery in the circuit. Making or breaking an alternator connection with a heavy load on the circuit will sometimes result in regulator damage.
The starting motor is a device used to rotate the flywheel of an engine fast enough to start the engine. Alternator Charging Circuit
(Negative Ground System Illustrated)
24 VOLT DIRECT ELECTRIC STARTING MOTORThe starting motor used with direct electric start incorporates a solenoid. The action of the solenoid engages the pinion with the ring gear on the engine flywheel, when the solenoid is energized. The pinion always engages before the electric contacts in the solenoid closes the circuit between the battery and the starting motor. An over-running clutch protects the starting motor from being overspeeded. Releasing the start-switch disengages the pinion from the ring gear on the flywheel.A solenoid is a magnetic switch that utilizes low current to close a high current circuit. The solenoid has an electromagnet with a movable core. There are contacts on the end of the core. The contacts are held open by a spring that pushes the core away from the magnetic center of the coil. Low current will energize the coil and form a magnetic field. The magnetic field draws the core to the center of the coil and the contacts close.
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107492-2064
INJECTION-PUMP ASSEMBLY