Information injection-pump assembly
ZEXEL
107492-2110
1074922110
Rating:
Service parts 107492-2110 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:
107492-2110
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
107492-2110
1074922110
Zexel num
Bosch num
Firm num
Name
107492-2110
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
11.8
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
7.5+-0.5
Pump speed
r/min
500
500
500
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(11.8)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
101
100
102
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=25deg+-5deg b=(41deg)+-3deg
----------
----------
a=25deg+-5deg b=(41deg)+-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.
(3)After setting the stopper bolt, confirm non-injection at speed dd.
----------
aa=40mm bb=1450r/min cc=1-0.5mm dd=350r/min
----------
a=36.5deg+-5deg b=(45deg)+-5deg
----------
aa=40mm bb=1450r/min cc=1-0.5mm dd=350r/min
----------
a=36.5deg+-5deg b=(45deg)+-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(11.8)+1.55mm
----------
----------
N1=1500r/min Ra=R1(11.8)+1.55mm
----------
Information:
Fuel Return Manifold Leaks and/or Leaks at Fuel Return Boots or Connectors ... Remove the valve cover(s). Make a visual inspection of the fuel return manifold, fuel return boots, and connectors. Boots and/or connectors with damage, or wrongly installed, will let fuel get into the oil. If you do not see leaks during the visual inspection, start the engine and visually inspect while the engine is running. Boots and/or connectors can cause leakage if the fuel return line has a restriction.Loose Fuel Injection Nozzle Nut(s) ... A loose fuel injection nozzle nut can cause fuel leakage. Tighten nozzle nut(s) to 30 5 lb. ft. (4,1 0,7 mkg).Defective Fuel Nozzle(s) ... Check fuel nozzle(s) for cracks in inlet fitting, inlet line, or nozzle body. If you do not see a crack, start the engine and visually inspect each nozzle for leaks. Cracks in the inlet fitting and nozzle body are nozzle defects. Cracks in the inlet line are caused by the nozzle not being tightened correctly.Defective Diaphragm in Fuel Transfer Pump ... A defective diaphragm will cause fuel leakage through the orifice in the fuel transfer pump housing. If you do not see leakage, make sure the orifice is open. Start the engine and again look for possible leakage. If the pump has leaks, install a new pump.Loose Fuel Injection Pump Retaining Bushing ... Loose retaining bushings will not hold the barrel of the injection pump correctly against the seat in the pump housing and fuel can get into the crankcase. A loose bushing can cause the engine to misfire or cause fuel leakage to the outside of the pump housing. Remove the fuel lines at the fuel injection pump and tighten each retaining bushing to 100 10 lb. ft. (13,8 1,4 mkg). To tighten the three rear retaining bushings the pump housing must be removed from the engine.Fuel Leaks Between Injection Pump Barrel(s) and Injection Pump Housing ... Dirt or foreign material under the barrel of the fuel injection pump will cause fuel leakage into the crankcase. Remove the housing of the fuel injection pump and the governor from the engine. Remove the plunger and barrel assemblies from the pump housing. Inspect the seat area of the barrel and housing. Be sure the seat is smooth and flat. Check the timing dimension and adjust as necessary. Install the fuel injection pumps. *Worn Fuel Injection Pumps ... It is possible for one or more of the plunger and barrel assemblies to be worn enough to cause fuel leakage between the plunger and barrel. Remove the housing of the fuel injection pump and the governor from the engine. Test the fuel injection pump on the test bench for fuel injection pumps. If a test bench is not available, install new plunger and barrel assemblies in place of those with damage.*Authorized dealers are equipped with the necessary tools and personnel familiar with disassembly and assembly procedures to perform these services.
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Group cross 107492-2110 ZEXEL
Mitsubishi
107492-2110
INJECTION-PUMP ASSEMBLY