107692-2090 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1076922090

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 107692-2090 1076922090

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Cross reference number

ZEXEL 107692-2090 1076922090

Zexel num

Bosch num

Firm num

Name

107692-2090

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 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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

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

Adjusting point -

Rack position 12.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 118.5 116.5 120.5

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.6)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 118.5 117.5 119.5

Basic *

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

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+1.95

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 119 115 123

Fixing the lever *

Boost pressure kPa 33.3 33.3

Boost pressure mmHg 250 250

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 R2-1.1

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 250 250 250

Rack position R2[R1-1. 45]

Boost pressure kPa 20 20 20

Boost pressure mmHg 150 150 150

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 1.17 1.16 1.18

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 2.8 2.6 3

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 0.9

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=AB89 BCL=1.1+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=38mm
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a=32deg+-5deg b=34deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper screw so that speed = bb and the rack position = cc and confirm non-injection.
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aa=30mm bb=0r/min cc=0.5+-0.3mm
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a=35deg+-5deg b=45deg+-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
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aa=2deg bb=5.6+-0.03mm
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a=(0deg) b=(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 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=275r/min Ra=7.5+-0.1mm
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0000002301 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)+1.95mm
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Information:

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 Clutch - Check/Adjust/Lubricate Air Starter & Air Tank (if equipped) - Check/Adjust/Drain water Engine Air Cleaner - Check service indicator SR4 Generator - Inspect/CheckEvery 1,100 L (300 gal) of Fuel or 50 Service Hours*
Dust Collector - Clean Light Duty Air Cleaner (If Equipped) - ReplaceEvery 2,800 L (750 gal) of Fuel 125 Service Hours*
Clutch - Check/Adjust/Lubricate Generator Space Heaters (If Equipped) - CheckEvery 5,600 L (1,500 gal) of Fuel or 250 Service Hours*
Scheduled Oil Sampling (S O S)1 - Obtain Sample Engine Oil and Filter(s)1 - Change Crankcase Breather1 - Clean Engine Valve Lash (Between First 250 and 1000 Service Hours Only)1 - Check/Adjust Cooling System - Test for supplemental coolant additive concentration Fuel System - Clean/Replace filters, Drain water from fuel tank Radiator Fins, Aftercooler, Belts, and Hoses - Inspect/Check Fan Drive Bearing - Lubricate Batteries - Check/Clean Magnetic Pickup (At First Oil Change Only - Inspect/Clean1These maintenance requirements are to be performed between the 250 and the 1000 Service Hour interval for Turbocharged (T) Engines ONLY. Refer to 500 Hour interval for Naturally Aspirated (NA) Engines.Every 11,250 L (3,000 gal) of Fuel or 500 Service Hours (NA Only)*
Scheduled Oil Sampling (S O S) Analysis - Obtain Sample Engine Oil and Filter(s) - Change Crankcase Breather - Clean Engine Valve Lash (Between First 500 and 1000 Service Hours Only) - Check/AdjustEvery 22,500 L (6,000 gal) of Fuel or 1000 Service Hours*
Engine Protection Devices - Inspect SR4 Generator and Control Panel - Inspect Fuel Control Linkage - LubricateEvery 45,000 L (12,000 gal) of Fuel 2000 Service Hours*
Engine Valve Lash, Valve Rotators, Fuel Ratio Control, Set Point, and Low Idle - Check/Adjust Fuel Injection Nozzles - Test/Clean/Replace Turbocharger - Inspect Engine Mounts - Inspect Crankshaft Vibration Damper - Inspect SR4 Generator - Check/Inspect Clean/LubricateEvery 68,220 L (18,000 gal) of Fuel or 3000 Service Hours or Two Years*
Cooling System - Add Extender (Extended Life Coolant Only) Cooling System - Drain/Clean/Replace Coolant - Conventional Coolant/Antifreeze Only Water Pump Seal - Inspect/Replace Hoses - Replace Thermostat - ReplaceEvery 90,000 L (24,000 gal) of Fuel or 4000 Service Hours*
Magnetic Pickup - Inspect/Clean SR4 Generator - Check/Inspect/Clean/LubricateEvery 135,000 L (36,000 gal) of fuel or 6,000 Service Hours or Four Years
Cooling System - Drain/Flush/Replace Coolant (Extended Life Coolant Only)*Perform previous maintenance interval items first.