Information injection-pump assembly
ZEXEL
107691-2620
1076912620
Rating:
Service parts 107691-2620 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
ME075517
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107691-2620
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
107691-2620
1076912620
Zexel num
Bosch num
Firm num
Name
107691-2620
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
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
RED3 control unit part number
407910-3
960
RED3 rack sensor specifications
mm
19
PS/ACT control unit part no.
407910-3
03*
Selector switch no.
03
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
16
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
5.1
5.07
5.13
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
(12.5)
Vist
V
1.98
1.98
1.98
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
140
139
141
Max. variation between cylinders
%
0
-3
3
Basic
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
PS407910-303*
V
1.75+-0.
01
PS407910-303*
mm
3.1+-0.0
5
Injection quantity adjustment_02
Rack position
(6.6)
Vist
V
2.9
2.8
3
Pump speed
r/min
410
410
410
Average injection quantity
mm3/st.
16.5
14.7
18.3
Max. variation between cylinders
%
0
-15
15
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5+-0.03
PS407910-303*
V
V1-0.05+
-0.01
PS407910-303*
mm
5+-0.03
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Governor adjustment
Pump speed
r/min
1050--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
0
-0.5
0
Governor adjustment_03
Pump speed
r/min
1075
Advance angle
deg.
-1.5
-2
-1
Remarks
Finish
Finish
0000001201
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2
1.95
2.05
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
5.1
5.07
5.13
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
1.95
2.05
Output voltage
V
1.17
1.16
1.18
Adjustment
*
_05
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.1
5.07
5.13
Output voltage
V
2.8
2.6
3
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
0.95
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=1mm bb=20mm
----------
a=39deg+-5deg b=37deg+-5deg
----------
aa=1mm bb=20mm
----------
a=39deg+-5deg b=37deg+-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=2deg bb=5.1+-0.03mm
----------
a=(2deg)
----------
aa=2deg bb=5.1+-0.03mm
----------
a=(2deg)
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
----------
----------
----------
----------
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 19 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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----------
----------
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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=1.6V
----------
----------
V1=1.6V
----------
Information:
2. Remove oil filter base support (2), air line (3) and oil level gauge tube (4). Remove the right lifting eye (1) and the left lifting eye. 3. Remove glow plug leads (5) and the 3/8 in. bolts from the cylinder head. Glow plug leads are on the precombustion engine only.4. Install two 5/16"-18 NC forged eyebolts and nuts in the cylinder head. Fasten a hoist to the cylinder head.5. Remove cylinder head bolts (6) and the washers. Clean all debris or foreign material from the "V" of the engine before removal of the cylinder head.6. Remove the cylinder head. Weight of the cylinder head is 200 lb. (90 kg). Put a cover over the intake manifold portion of the cylinder head to keep dirt and foreign material out.
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
A new spacer plate gasket must be installed when the cylinder head is removed. See REMOVE AND INSTALL SPACER PLATE.Install Cylinder Head
1. Clean the spacer plate and the bottom surface of the cylinder head. Put a new cylinder head gasket (3) and seals (4) in position on the spacer plate as shown.2. Fasten a hoist to cylinder head (2) and put it in position over dowels (5) in the cylinder block.3. Put clean SAE 30 oil on the threads of the bolts that hold the cylinder head in position. Install the bolts and washers and tighten them to the correct torque as follows: a) Tighten bolts 1 through 14 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten bolts 1 through 14 in number sequence to a torque of 330 15 lb.ft. (447 20 N m).c) Tighten bolts 1 through 14 again in number sequence to a torque of 330 15 lb.ft. (447 20 N m).d) Install the rocker shaft assembly and push rods.e) Tighten bolts 15 through 18 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).f) Tighten bolts 15 through 18 in number sequence to a torque of 330 15 lb.ft. (447 20 N m).g) Tighten bolts 15 through 18 again in number sequence to a torque of 330 15 lb.ft. (447 20 N m).4. Install the glow plug leads and the 3/8 in. bolts in the cylinder head. Tighten the bolts to a torque of 32 5 lb.ft. (43 7 N m). If studs (1) were removed, install new studs and tighten them to a torque of 20 3 lb.ft. (25 4 N m).5. Make an adjustment for the valve clearance. The clearance must be .015 .003 in. (0.38 0.07 mm) for intake and .030 .003 in. (0.76 0.07 mm) for exhaust. See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING.6. Install the left and right lifting eyes.7. Install the oil level gauge tube, air line and oil
Do not put the cylinder head down on a flat surface. This can cause damage to the fuel injection valves.
A new spacer plate gasket must be installed when the cylinder head is removed. See REMOVE AND INSTALL SPACER PLATE.Install Cylinder Head
1. Clean the spacer plate and the bottom surface of the cylinder head. Put a new cylinder head gasket (3) and seals (4) in position on the spacer plate as shown.2. Fasten a hoist to cylinder head (2) and put it in position over dowels (5) in the cylinder block.3. Put clean SAE 30 oil on the threads of the bolts that hold the cylinder head in position. Install the bolts and washers and tighten them to the correct torque as follows: a) Tighten bolts 1 through 14 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).b) Tighten bolts 1 through 14 in number sequence to a torque of 330 15 lb.ft. (447 20 N m).c) Tighten bolts 1 through 14 again in number sequence to a torque of 330 15 lb.ft. (447 20 N m).d) Install the rocker shaft assembly and push rods.e) Tighten bolts 15 through 18 in number sequence to a torque of 200 20 lb.ft. (270 25 N m).f) Tighten bolts 15 through 18 in number sequence to a torque of 330 15 lb.ft. (447 20 N m).g) Tighten bolts 15 through 18 again in number sequence to a torque of 330 15 lb.ft. (447 20 N m).4. Install the glow plug leads and the 3/8 in. bolts in the cylinder head. Tighten the bolts to a torque of 32 5 lb.ft. (43 7 N m). If studs (1) were removed, install new studs and tighten them to a torque of 20 3 lb.ft. (25 4 N m).5. Make an adjustment for the valve clearance. The clearance must be .015 .003 in. (0.38 0.07 mm) for intake and .030 .003 in. (0.76 0.07 mm) for exhaust. See VALVE CLEARANCE SETTING in TESTING AND ADJUSTING.6. Install the left and right lifting eyes.7. Install the oil level gauge tube, air line and oil
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107691-2620
INJECTION-PUMP ASSEMBLY