Information injection-pump assembly
ZEXEL
107691-2553
1076912553
Rating:
Service parts 107691-2553 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
ME075583
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Include in #1:
107691-2553
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
107691-2553
1076912553
Zexel num
Bosch num
Firm num
Name
107691-2553
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=29deg+-5deg b=26deg+-5deg
----------
aa=16mm bb=1mm
----------
a=29deg+-5deg b=26deg+-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=(1deg)
----------
aa=5deg bb=5.6+-0.03mm
----------
a=(1deg)
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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0000001401
C:Shim
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----------
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----------
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:
10. Remove pin (18), spring and plunger from control lever (14). 11. Remove bearings (19) and two seals (20) from governor housing (13). 12. Remove seat (21), spring washer (22), flat washer (24), spring washer (23) and spring (25). 13. Remove washer (27) from governor bolt (26).14. Remove ring (28) from seat (29). 15. Remove dowel (30) from seat (29). Remove seat (29) and governor bolt (26) as a unit. Remove bolt (26) from seat (29). 16. Remove washer (31), spring (32), washer (33) and sleeve (34) from the servo piston valve. 17. Remove ring (38), large race (37), bearing (35) and small race (36) from sleeve (34). 18. Remove lock (40) from flyweight assembly (39). Remove flyweight assembly (40). 19. Bend the locks from bolts (41) and remove bolts (41).20. Remove bracket (42) and the servo piston assembly as a unit. 21. Remove piston (44) from pin (43). Remove pin (43) from bracket (42). 22. Remove sleeve (45) and valve (46) from piston (44). Remove O-ring seal (47) from sleeve (45). 23. Remove shaft (48) from bracket (42) with a hammer and punch.24. Remove lever (49) from bracket (42). 25. Hit (tap) lightly on cylinder (50) to remove it from the governor plate. 26. Remove O-ring seals (51) from cylinder (50). 27. Remove spiral ring (53), and then remove dowel (52) behind the spiral ring. 28. Remove drive assembly (54) and stop (55) from drive gear (56). 29. Turn the governor plate over and remove snap ring (57) from drive gear (56) with tool (B).30. Remove drive gear (56) from the governor plate. 31. If a replacement is needed, remove dowels (59), (60) and (61).32. Remove bearing (58) from the governor plate with tooling (A).Assemble Governor
1. If a replacement of the dowels in the governor plate is necessary, see illustration for correct installation dimensions. 2. Install bearing (1) for drive gear (2) in governor plate (3) with tooling (A) until it is .020 .010 in. (0.51 0.25 mm) below the top surface of the governor plate. 3. Put a small amount of clean engine oil on the inside diameter of bearing (1). Install drive gear (2) in governor plate (3). 4. Turn governor plate (3) over and install snap ring (4) that holds drive gear (2) in place. 5. Install O-ring seals (6) on cylinder (5). 6. Put a small amount of clean engine oil on the O-ring seals on cylinder (5). Install cylinder (5) in the governor plate with the notch in the cylinder in alignment with the bolt hole in the governor plate as shown.7. Install the O-ring seal on sleeve (9).8. Put a small amount of clean engine oil on piston (7), sleeve (9) and valve (8). Install sleeve (9) on piston (7) and valve (8) in piston (7) as shown.9. Install the servo piston assembly in cylinder (5). The valve (8), sleeve (9) and piston (7) are parts of the servo piston assembly. 10. Put lever (11) in position in bracket
1. If a replacement of the dowels in the governor plate is necessary, see illustration for correct installation dimensions. 2. Install bearing (1) for drive gear (2) in governor plate (3) with tooling (A) until it is .020 .010 in. (0.51 0.25 mm) below the top surface of the governor plate. 3. Put a small amount of clean engine oil on the inside diameter of bearing (1). Install drive gear (2) in governor plate (3). 4. Turn governor plate (3) over and install snap ring (4) that holds drive gear (2) in place. 5. Install O-ring seals (6) on cylinder (5). 6. Put a small amount of clean engine oil on the O-ring seals on cylinder (5). Install cylinder (5) in the governor plate with the notch in the cylinder in alignment with the bolt hole in the governor plate as shown.7. Install the O-ring seal on sleeve (9).8. Put a small amount of clean engine oil on piston (7), sleeve (9) and valve (8). Install sleeve (9) on piston (7) and valve (8) in piston (7) as shown.9. Install the servo piston assembly in cylinder (5). The valve (8), sleeve (9) and piston (7) are parts of the servo piston assembly. 10. Put lever (11) in position in bracket
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107691-2553
INJECTION-PUMP ASSEMBLY