Information injection-pump assembly
ZEXEL
107691-2551
1076912551
Rating:
Cross reference number
ZEXEL
107691-2551
1076912551
Zexel num
Bosch num
Firm num
Name
107691-2551
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
RED3 control unit part number
407910-2
470
RED3 rack sensor specifications
mm
15
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
Rack position
(11)
Vist
V
1.8
1.8
1.8
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
120.5
119.5
121.5
Max. variation between cylinders
%
0
-3
3
Basic
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
5
Injection quantity adjustment_02
Rack position
(6)
Vist
V
2.8
2.7
2.9
Pump speed
r/min
440
440
440
Average injection quantity
mm3/st.
15.5
13.7
17.3
Max. variation between cylinders
%
0
-15
15
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5.5+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Governor adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.5
Governor adjustment_03
Pump speed
r/min
1470
Advance angle
deg.
3
2.5
3.5
Remarks
Finish
Finish
0000001201
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:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=16mm bb=1mm
----------
a=26deg+-5deg b=29deg+-5deg
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aa=16mm bb=1mm
----------
a=26deg+-5deg b=29deg+-5deg
0000000901
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)Pre-stroke: bb
----------
aa=5deg bb=5.6+-0.03mm
----------
a=(0deg)
----------
aa=5deg bb=5.6+-0.03mm
----------
a=(0deg)
Stop lever angle
(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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0000001301
A : Stopper pin
B: Connector
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----------
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----------
0000001401
C:Shim
----------
----------
----------
----------
0000001501
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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0000001701
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 15 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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0000001901 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 (154610-0620)
(1)At governor side rack sensor output voltage V1, adjust the bobbin (A) so that the drive side rack sensor output voltage is VR+-0.01.
(2)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)
----------
V1=1V
----------
----------
V1=1V
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Information:
start by:a) remove fuel ratio controlb) remove shut off solenoid 1. Put a mark of identification on the shaft and lever (1) for correct location at assembly. Loosen the bolt and remove lever (1) from the shaft. 2. Remove the bolts, cover (3) and the gasket.3. Remove the bolt, high idle housing (2) and the gasket. 4. Remove the bolt and housing (4) from the governor. 5. Remove bolt (6) from the stop collar.6. Remove stop collar (5) and the spring from the shaft. 7. Remove the plug from the fuel injection pump housing and install tool (A) with square end (flat end) down. Move the governor control to the "FUEL ON" position until the right rack stops against the timing pin. The racks are now in the center (zero) position. 8. Remove bolts (8) that hold the governor housing to the fuel injection pump housing.9. Remove governor housing (7). 10. Disconnect lines (10) and (11) at the governor control plate.11. Remove the bolts, governor control plate (9) and gasket.
Cover the fuel injection pump housing to keep dirt and all foreign material out of the pump housing.
The drive assembly must be removed from the governor control plate before the control plate can be installed. 12. Remove retainer ring (12) from the drive assembly. 13. Remove dowel (14) and drive assembly (13) from the governor control plate.Install Governor (Later)
Make sure there is no dirt or foreign material in the pump housing.
1. Put gasket (2) in position and install governor control plate (1) and the bolts. 2. Put governor drive (3) in position. Make an alignment of the groove (slot) in the bottom end of the governor drive with the notch in the end of the drive pinion assembly.3. Align the marks on the top of drive (3), stop (4) and the gear. 4. Install dowel (5) in the hole in the gear and stop (4). 5. Install retainer ring (6) on the gear. 6. Put the gasket and governor housing (7) in position on the plate. Install the bolts.7. Connect two lines (8) to the plate. 8. Put spring (11) and collar (9) in position on the shaft. Make an alignment of screw (10) and the groove in the shaft. Tighten screw (10).9. Check the fuel rack setting at this time. See FUEL RACK SETTING in TESTING AND ADJUSTING. 10. If nut (13) was loosened it must be tightened at this time. Tighten nut (13) to a torque of 9 3 lb.ft. (12 4 N m).11. Put the gasket and cover (12) in position. Make sure lever (14) is in position under the collar. Install the bolt that holds cover (12) to the housing. 12. Put the gasket and cover (16) in position and install the bolt.13. Install the gasket, plate (15) and the bolts. 14. Make an alignment of the mark on the shaft with mark on lever (17) and install the lever. Tighten the bolt.
If the lever and the shaft are not in correct alignment,
Cover the fuel injection pump housing to keep dirt and all foreign material out of the pump housing.
The drive assembly must be removed from the governor control plate before the control plate can be installed. 12. Remove retainer ring (12) from the drive assembly. 13. Remove dowel (14) and drive assembly (13) from the governor control plate.Install Governor (Later)
Make sure there is no dirt or foreign material in the pump housing.
1. Put gasket (2) in position and install governor control plate (1) and the bolts. 2. Put governor drive (3) in position. Make an alignment of the groove (slot) in the bottom end of the governor drive with the notch in the end of the drive pinion assembly.3. Align the marks on the top of drive (3), stop (4) and the gear. 4. Install dowel (5) in the hole in the gear and stop (4). 5. Install retainer ring (6) on the gear. 6. Put the gasket and governor housing (7) in position on the plate. Install the bolts.7. Connect two lines (8) to the plate. 8. Put spring (11) and collar (9) in position on the shaft. Make an alignment of screw (10) and the groove in the shaft. Tighten screw (10).9. Check the fuel rack setting at this time. See FUEL RACK SETTING in TESTING AND ADJUSTING. 10. If nut (13) was loosened it must be tightened at this time. Tighten nut (13) to a torque of 9 3 lb.ft. (12 4 N m).11. Put the gasket and cover (12) in position. Make sure lever (14) is in position under the collar. Install the bolt that holds cover (12) to the housing. 12. Put the gasket and cover (16) in position and install the bolt.13. Install the gasket, plate (15) and the bolts. 14. Make an alignment of the mark on the shaft with mark on lever (17) and install the lever. Tighten the bolt.
If the lever and the shaft are not in correct alignment,
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107691-2551
INJECTION-PUMP ASSEMBLY