Information injection-pump assembly
ZEXEL
107692-2084
1076922084
Rating:
Cross reference number
ZEXEL
107692-2084
1076922084
Zexel num
Bosch num
Firm num
Name
107692-2084
INJECTION-PUMP ASSEMBLY
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
131424-8420
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
5.6
5.57
5.63
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
12.6
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
117
115
119
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
PS407980-224*
V
1.75+-0.
01
PS407980-224*
mm
3.6+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
7.5+-0.5
Pump speed
r/min
465
465
465
Average injection quantity
mm3/st.
14
12.2
15.8
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
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(12.6)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
117
116
118
Basic
*
Fixing the lever
*
Boost pressure
kPa
34.7
34.7
Boost pressure
mmHg
260
260
PS407980-224*
V
1.75+-0.
01
PS407980-224*
mm
3.6+-0.0
5
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.55
Pump speed
r/min
1350
1350
1350
Average injection quantity
mm3/st.
110
106
114
Fixing the lever
*
Boost pressure
kPa
34.7
34.7
Boost pressure
mmHg
260
260
PS407980-224*
V
1.75+-0.
01
PS407980-224*
mm
3.6+-0.0
5
Boost compensator adjustment
Pump speed
r/min
250
250
250
Rack position
R2-1.25
Boost pressure
kPa
8
6.7
9.3
Boost pressure
mmHg
60
50
70
Boost compensator adjustment_02
Pump speed
r/min
250
250
250
Rack position
R2(R1-1.
35)
Boost pressure
kPa
21.3
21.3
21.3
Boost pressure
mmHg
160
160
160
0000001601
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
24
23.5
24.5
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
24
23.5
24.5
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
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)Boost compensator stroke: BCL
----------
T1=AC34 BCL=1.25+-0.1mm
----------
----------
T1=AC34 BCL=1.25+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=38mm
----------
a=29deg+-5deg b=39deg+-3deg
----------
aa=38mm
----------
a=29deg+-5deg b=39deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Normal engine position (equivalent to R = bb).
(3)Set the stopper bolt at rack position = cc and speed = dd and confirm non-injection
----------
aa=47mm bb=17.4mm cc=3.5+-0.3mm dd=0r/min
----------
a=4deg+-5deg b=(31deg) c=41deg+-5deg
----------
aa=47mm bb=17.4mm cc=3.5+-0.3mm dd=0r/min
----------
a=4deg+-5deg b=(31deg) c=41deg+-5deg
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper to align with the pointer's groove.
(4)Damper
(5)Pointer
(6)B.T.D.C.: aa
(7)Pre-stroke: bb
----------
aa=2deg bb=5.6+-0.03mm
----------
a=(0deg) b=(40deg)
----------
aa=2deg bb=5.6+-0.03mm
----------
a=(0deg) b=(40deg)
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 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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----------
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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=1350r/min Ra=R1(12.6)+1.55mm
----------
----------
N1=1350r/min Ra=R1(12.6)+1.55mm
----------
Information:
Calibration
Refer to the complete Oil and Filter change procedure before performing Calibration (if applicable).Your engine may use a dipstick that has a FULL RANGE zone rather than the traditional FULL mark. The FULL RANGE is between the ADD and FULL marks (X-Y). This dipstick allows for variations in engine installations. Engine oil level will vary, depending on angle (front to back tilt) and slant sideways tilt).To determine the correct FULL mark in the FULL RANGE zone and prevent overfilling or under filling the crankcase, it is important to calibrate (or verify the calibration of) the dipstick at the first oil change.To verify the ADD mark and establish the actual FULL mark in the FULL RANGE zone of the dipstick, use the following procedure. This procedure is correct for use with either the non-spacer plate oil pan or the spacer plate oil pan. Sump capacities and oil levels are the same for each oil pan. The engine must rest on a level surface for this procedure.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
1. Operate the engine until it reaches normal operating temperature.2. Stop the engine. Remove the crankcase drain plug(s). Let the oil drain from the crankcase for 20 minutes.3. Remove the used oil filter(s). Install the new oil filter(s). Install the crankcase drain plug(s) and tighten to 70 14 N m (50 10 lb ft).4. Add 18 L (19 qt) of oil for 3306B engines or 16 L (17 qt) of oil for 3304B engines. Allow the oil to drain back to the sump for a minimum of five minutes.5. Ensure that the oil level gauge is seated. Check the oil level on the oil level gauge. The oil level should be at the ADD mark. If the oil level is not at the existing ADD mark, use an engraving tool to grind off the mark and engrave the new ADD level.6. Add 6 L (6 qt) of oil for 3306B engines or 2.5 L (2.5 qt) of oil for 3304B engines into the sump. Allow enough time for the oil to drain into the sump.7. Ensure that the oil level gauge is seated. Check the oil level on the oil level gauge. The oil level should be at the FULL mark. If the oil level is not at the existing FULL mark, use an engraving tool to grind off the mark and engrave the new FULL level.
Remote mounted or auxiliary oil filters require additional oil. For all information about auxiliary oil filters, refer to the OEM instructions.
8. Add an additional 4 L (4 qt) of oil into the sump for both the 3306B and the 3304B engines. Total fill capacity for the 3306B engine is 27.5 L (29 qt) Total fill capacity for the 3304B engine is 22.5 L (23.5 qt).
To prevent crankshaft or bearing damage, crank the engine with the fuel OFF in order to fill all of the oil
Refer to the complete Oil and Filter change procedure before performing Calibration (if applicable).Your engine may use a dipstick that has a FULL RANGE zone rather than the traditional FULL mark. The FULL RANGE is between the ADD and FULL marks (X-Y). This dipstick allows for variations in engine installations. Engine oil level will vary, depending on angle (front to back tilt) and slant sideways tilt).To determine the correct FULL mark in the FULL RANGE zone and prevent overfilling or under filling the crankcase, it is important to calibrate (or verify the calibration of) the dipstick at the first oil change.To verify the ADD mark and establish the actual FULL mark in the FULL RANGE zone of the dipstick, use the following procedure. This procedure is correct for use with either the non-spacer plate oil pan or the spacer plate oil pan. Sump capacities and oil levels are the same for each oil pan. The engine must rest on a level surface for this procedure.
Hot oil and hot components can cause personal injury. Do not allow hot oil or hot components to contact the skin.
1. Operate the engine until it reaches normal operating temperature.2. Stop the engine. Remove the crankcase drain plug(s). Let the oil drain from the crankcase for 20 minutes.3. Remove the used oil filter(s). Install the new oil filter(s). Install the crankcase drain plug(s) and tighten to 70 14 N m (50 10 lb ft).4. Add 18 L (19 qt) of oil for 3306B engines or 16 L (17 qt) of oil for 3304B engines. Allow the oil to drain back to the sump for a minimum of five minutes.5. Ensure that the oil level gauge is seated. Check the oil level on the oil level gauge. The oil level should be at the ADD mark. If the oil level is not at the existing ADD mark, use an engraving tool to grind off the mark and engrave the new ADD level.6. Add 6 L (6 qt) of oil for 3306B engines or 2.5 L (2.5 qt) of oil for 3304B engines into the sump. Allow enough time for the oil to drain into the sump.7. Ensure that the oil level gauge is seated. Check the oil level on the oil level gauge. The oil level should be at the FULL mark. If the oil level is not at the existing FULL mark, use an engraving tool to grind off the mark and engrave the new FULL level.
Remote mounted or auxiliary oil filters require additional oil. For all information about auxiliary oil filters, refer to the OEM instructions.
8. Add an additional 4 L (4 qt) of oil into the sump for both the 3306B and the 3304B engines. Total fill capacity for the 3306B engine is 27.5 L (29 qt) Total fill capacity for the 3304B engine is 22.5 L (23.5 qt).
To prevent crankshaft or bearing damage, crank the engine with the fuel OFF in order to fill all of the oil
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107692-2084
INJECTION-PUMP ASSEMBLY