Information injection-pump assembly
ZEXEL
107691-2633
1076912633
Rating:
Service parts 107691-2633 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
ME086835
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107691-2633
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
107691-2633
1076912633
Zexel num
Bosch num
Firm num
Name
107691-2633
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.
01
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
15
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
1-5-3-6-
2-4
Pre-stroke
mm
5.1
5.07
5.13
Beginning of injection position
Drive side NO.1
Drive 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
(9.7)
Vist
V
2.39
2.39
2.39
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
96
95
97
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
2.25+-0.
01
PS407910-303*
mm
3.1+-0.0
5
Injection quantity adjustment_02
Rack position
(6.5)
Vist
V
2.9
2.8
3
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
16
14.5
17.5
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
-
Advance angle
deg.
0
0
0
Remarks
Measure speed (beginning of operation).
Measure speed (beginning of operation).
Governor adjustment_02
Pump speed
r/min
-
Advance angle
deg.
0
-0.5
0
Remarks
Measure the actual speed.
Measure the actual speed.
Governor adjustment_03
Pump speed
r/min
-
Advance angle
deg.
-1.3
-1.8
-0.8
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
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
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
5.1
5.07
5.13
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:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=39.5deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=39.5deg+-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=6deg bb=5.1+-0.03mm
----------
a=(7deg)
----------
aa=6deg bb=5.1+-0.03mm
----------
a=(7deg)
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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----------
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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 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.
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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:
start by:a) remove oil pump 1. Check each main bearing cap (2) for its location on the engine. Each cap has an arrow (1) to show the front of the block and a number (3) which gives the location of that cap.2. Remove No. 2 through No. 4 main bearing caps from the engine. Remove the lower bearings from the caps.3. Remove the thrust plate from each side of the No. 3 upper main bearing. 4. Turn the crankshaft until tool (A) can be installed in oil hole (4). Turn the crankshaft in the direction which will push the upper main bearing out, tab end first.
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and the cylinder block. This will cause damage to the crankshaft and block.
5. Install lower bearings in the bearing caps.6. Install upper bearing in the cylinder block with tool (A). Be sure tab (5) on the back of the bearings fits in the groove of the caps and cylinder block.
When bearing caps are installed, make sure the caps are installed with the part number toward the front of the engine and the number on the bottom of the cap is the same as the number on the camshaft side of the engine.
When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with Plastigage (B). The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary to hold the crankshaft up. Do not turn crankshaft when Plastigage is in position to check clearance.7. Check the bearing clearance with tool (B) as follows: a) Put tool (B) in position as shown.b) Put clean oil on the threads of the cap bolts. Install the caps and cap bolts, finger tight.c) Tighten the bolts on the tab end of the caps first to a torque of 190 10 lb.ft. (260 14 N m).d) Tighten the bolts on the other end of the caps to a torque of 190 10 lb.ft. (260 14 N m). e) Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end 120°. Tighten the bolts on the tab end of the cap 120° more. Make sure the main bearing caps are installed with their identification number (7) in alignment with the identification number on the left side of the cylinder block and arrow (6) toward the front of the block.8. Remove the main bearing caps and tool (B).9. Measure the width of the Plastigage to determine the bearing clearance. The clearance for new bearings must be .0036 to .0073 in. (0.091 to 0.186 mm). The maximum clearance for used
If the crankshaft is turned in the wrong direction, the tab of the bearing will be pushed between the crankshaft and the cylinder block. This will cause damage to the crankshaft and block.
5. Install lower bearings in the bearing caps.6. Install upper bearing in the cylinder block with tool (A). Be sure tab (5) on the back of the bearings fits in the groove of the caps and cylinder block.
When bearing caps are installed, make sure the caps are installed with the part number toward the front of the engine and the number on the bottom of the cap is the same as the number on the camshaft side of the engine.
When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with Plastigage (B). The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, such as on an engine stand, it is not necessary to hold the crankshaft up. Do not turn crankshaft when Plastigage is in position to check clearance.7. Check the bearing clearance with tool (B) as follows: a) Put tool (B) in position as shown.b) Put clean oil on the threads of the cap bolts. Install the caps and cap bolts, finger tight.c) Tighten the bolts on the tab end of the caps first to a torque of 190 10 lb.ft. (260 14 N m).d) Tighten the bolts on the other end of the caps to a torque of 190 10 lb.ft. (260 14 N m). e) Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end 120°. Tighten the bolts on the tab end of the cap 120° more. Make sure the main bearing caps are installed with their identification number (7) in alignment with the identification number on the left side of the cylinder block and arrow (6) toward the front of the block.8. Remove the main bearing caps and tool (B).9. Measure the width of the Plastigage to determine the bearing clearance. The clearance for new bearings must be .0036 to .0073 in. (0.091 to 0.186 mm). The maximum clearance for used
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107691-2633
INJECTION-PUMP ASSEMBLY