107492-2000 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1074922000


107492-2000 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 107492-2000 1074922000

Cross reference number

ZEXEL 107492-2000 1074922000


Zexel num
Bosch num
Firm num
Name
107492-2000 
 
   
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   105780-8140
Bosch type code   EF8511/9A
Nozzle   105780-0000
Bosch type code   DN12SD12T
Nozzle holder   105780-2080
Bosch type code   EF8511/9
Opening pressure MPa   17.2
Opening pressure kgf/cm2   175
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   8-3-600
Overflow valve   131424-7920
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   157 157 157
Tester oil delivery pressure kgf/cm2   1.6 1.6 1.6
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
Injection timing adjustment
Direction of rotation (viewed from drive side)
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
Difference between angles 1
Cal 1-3
deg.   90 89.75 90.25
Difference between angles 2
Cal 1-4
deg.   180 179.75 180.25
Difference between angles 3
Cyl.1-2
deg.   270 269.75 270.25
Injection quantity adjustment
Adjusting point   -
Rack position   13.3
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   108 106.4 109.6
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 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   9.6+-0.5
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   9 7.5 10.5
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(13.3)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   108 107 109
Basic   *
Fixing the lever   *
Boost pressure kPa   50.7 50.7
Boost pressure mmHg   380 380
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.55
Pump speed r/min   1550 1550 1550
Average injection quantity mm3/st.   108.7 104.7 112.7
Fixing the lever   *
Boost pressure kPa   50.7 50.7
Boost pressure mmHg   380 380
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(R1-0. 65)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   110 106 114
Fixing the lever   *
Boost pressure kPa   50.7 50.7
Boost pressure mmHg   380 380
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Injection quantity adjustment_06
Adjusting point   D
Rack position   R2-1.5
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   64.4 60.4 68.4
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   3.6+-0.0 3
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.6+-0.0 3
Boost compensator adjustment
Pump speed r/min   400 400 400
Rack position   R2-1.5
Boost pressure kPa   16.7 15.4 18
Boost pressure mmHg   125 115 135
Boost compensator adjustment_02
Pump speed r/min   400 400 400
Rack position   R2(R1-0. 65)
Boost pressure kPa   37.3 37.3 37.3
Boost pressure mmHg   280 280 280
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   *
_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   *
_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

Test data 107492-2000
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=F54 BCL=1.5+-0.1mm
----------

Speed control lever angle

Test data 107492-2000
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=26deg+-5deg b=40.5deg+-3deg

Stop lever angle

Test data 107492-2000
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed = cc.
----------
aa=1600r/min bb=5.4-0.5mm cc=300r/min
----------
a=20deg+-5deg b=31deg+-5deg

0000001301

Test data 107492-2000
(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=4deg bb=5.6+-0.03mm
----------
a=(130deg)

0000001401

Test data 107492-2000
(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

Test data 107492-2000
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107492-2000
C:Shim
----------

----------

0000001901

Test data 107492-2000
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

Test data 107492-2000
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump Adjustment of the rack sensor (-2320) 1. Rack limit adjustment (1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position. (2)Install the rod (e) to the block (c). (3)At the rack limit, set the distance between the pump end face and the rod (E) to L1. 2. Rack sensor (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at N1. (3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (4)Adjust the bobbin (a) so that the rack sensor output voltage becomes VR +-0.01(V). (5)Apply red paint to both the joint (b) and the nut (f) join, and the joint (b) and the pump join. Output voltage VR +-0.01(V), speed N1 r/min, rack position Ra mm
----------
L=43+-0.1mm N1=1550r/min Ra=R1(13.3)+1.55mm
----------




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