Information injection-pump assembly
ZEXEL
107692-1163
1076921163
ISUZU
8943954952
8943954952
Rating:
Service parts 107692-1163 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
8-94394-606-5
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107692-1163
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
107692-1163
1076921163
ISUZU
8943954952
8943954952
Zexel num
Bosch num
Firm num
Name
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.
00
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
11
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
1.9
1.87
1.93
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
Adjusting point
-
Rack position
13.3
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
102.5
100.9
104.1
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
PS407980-224*
V
1.88+-0.
01
PS407980-224*
mm
3.2+-0.0
5
PS407910-303*
V
1.88+-0.
01
PS407910-303*
mm
3.2+-0.0
5
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
9.1+-0.5
Pump speed
r/min
410
410
410
Average injection quantity
mm3/st.
18.5
16.7
20.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
PS407980-224*
V
V1-0.05+
-0.01
PS407980-224*
mm
4.9+-0.0
3
PS407910-303*
V
V1-0.05+
-0.01
PS407910-303*
mm
4.9+-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(13.3)
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
102.5
101.5
103.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
PS407980-224*
V
1.88+-0.
01
PS407980-224*
mm
3.2+-0.0
5
PS407910-303*
V
1.88+-0.
01
PS407910-303*
mm
3.2+-0.0
5
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2-1.9
Boost pressure
kPa
17.3
16
18.6
Boost pressure
mmHg
130
120
140
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-0.
35)
Boost pressure
kPa
46.7
46.7
46.7
Boost pressure
mmHg
350
350
350
0000001601
CU407980-224*
*
Actuator advancing type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5
4.95
5.05
Output voltage
V
2.83
2.82
2.84
Adjustment
*
Remarks
Output voltage V1
Output voltage V1
_02
CU407980-224*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
1.9
1.87
1.93
Output voltage
V
1.2
1
1.4
Confirmation
*
_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 advancing type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5
4.95
5.05
Output voltage
V
2.83
2.82
2.84
Adjustment
*
Remarks
Output voltage V1
Output voltage V1
_05
CU407910-303*
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
1.9
1.87
1.93
Output voltage
V
1.2
1
1.4
Confirmation
*
_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=AB48 BCL=1.9+-0.1mm
----------
----------
T1=AB48 BCL=1.9+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
(2)Use the pin at R = aa
----------
aa=35mm
----------
a=2deg+-5deg b=32deg+-3deg
----------
aa=35mm
----------
a=2deg+-5deg b=32deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)-
(2)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection.
(3)Use the pin above R = cc
----------
aa=0r/min bb=1.5+-0.3mm cc=40mm
----------
a=12deg+-5deg b=44deg+-5deg
----------
aa=0r/min bb=1.5+-0.3mm cc=40mm
----------
a=12deg+-5deg b=44deg+-5deg
0000001301
(1)Pump vertical direction
(2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)Pre-stroke: bb
----------
aa=22deg bb=1.9+-0.03mm
----------
a=(60deg)
----------
aa=22deg bb=1.9+-0.03mm
----------
a=(60deg)
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 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.
----------
----------
----------
----------
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=1250r/min Ra=R1(13.3)+2.35mm
----------
----------
N1=1250r/min Ra=R1(13.3)+2.35mm
----------
Information:
Final Fuel Filter
The filter element collects and holds contaminants and cannot be washed or otherwise restored.To remove the used filter, proceed as follows:1. Stop the engine and close the diesel fuel line valve (if equipped).2. Unscrew and remove filter. 3. Clean the gasket sealing surfaces on the filter bases. 4. Lubricate the new filter gasket with clean diesel fuel.
Do not pour fuel into the new filter element before installing. Prime the system as instructed in the topic, PRIMING THE FUEL SYSTEM.
5. Tighten the filter by hand until the gasket contacts the base, then tighten 1/2 to 3/4 turn more.6. Start the engine and run at 1000 rpm for several minutes and check for leaks. If the engine fails to start, prime the fuel system. See the topic TO PRIME THE SYSTEM. Keep New Fuel Filters On Hand
Extra filters should be kept on hand for replacement. Always keep filters wrapped in their original carton to insure against dust and dirt accumulation which will shorten the life of the filters or may cause damage to the fuel injection equipment.To Prime The System
If air is trapped in the fuel system, the diesel engine will either not start, or will misfire. Then it is necessary to prime the system.The fuel priming pump is mounted on the fuel filter base. If the fuel filter is changed or if the engine has run out of fuel, prime the fuel system as follows: 1. Be sure the fuel line valve is open and the engine shutoff control is off.2. Unlock the fuel priming pump.3. Operate priming pump until increased resistance is felt.4. Lock fuel priming pump.If the engine fails to start or continues to misfire or smoke, further bleeding is necessary. With engine running, or with the use of the priming pump, loosen fuel line nuts, one at a time, several times in succession and allow fuel to run until free of air bubbles. Tighten fuel line nuts.
LOOSENING FUEL INJECTION LINE TO BLEED SYSTEMFuel Injection Equipment
When improper fuel injection is affecting engine operation, a systematic check should be made to determine the cause. The most likely cause is dirt or water in the fuel. Drain the sediment from the fuel tank. Check the fuel pressure gauge as mentioned in the topic, FUEL FILTERING SYSTEM. Replace the filters if necessary. Then prime the fuel system until clean fuel reaches the fuel injection pumps. If the fuel system is air bound, priming the system will overcome the difficulty.If the engine is running irregularly, smoking, or knocking, a fuel injection valve may not be spraying the fuel properly.Direct Injection System
The fuel system of direct injection engines is essentially the same as precombustion chamber engines. The absence of the precombustion chamber requires a different fuel nozzle and adapter. Externally the direct injection fuel nozzle resembles the precombustion chamber nozzle except it is longer in length. Nozzle testing and replacement procedure is the same as illustrated for the precombustion chamber engines, except that an extracting tool is used to remove
The filter element collects and holds contaminants and cannot be washed or otherwise restored.To remove the used filter, proceed as follows:1. Stop the engine and close the diesel fuel line valve (if equipped).2. Unscrew and remove filter. 3. Clean the gasket sealing surfaces on the filter bases. 4. Lubricate the new filter gasket with clean diesel fuel.
Do not pour fuel into the new filter element before installing. Prime the system as instructed in the topic, PRIMING THE FUEL SYSTEM.
5. Tighten the filter by hand until the gasket contacts the base, then tighten 1/2 to 3/4 turn more.6. Start the engine and run at 1000 rpm for several minutes and check for leaks. If the engine fails to start, prime the fuel system. See the topic TO PRIME THE SYSTEM. Keep New Fuel Filters On Hand
Extra filters should be kept on hand for replacement. Always keep filters wrapped in their original carton to insure against dust and dirt accumulation which will shorten the life of the filters or may cause damage to the fuel injection equipment.To Prime The System
If air is trapped in the fuel system, the diesel engine will either not start, or will misfire. Then it is necessary to prime the system.The fuel priming pump is mounted on the fuel filter base. If the fuel filter is changed or if the engine has run out of fuel, prime the fuel system as follows: 1. Be sure the fuel line valve is open and the engine shutoff control is off.2. Unlock the fuel priming pump.3. Operate priming pump until increased resistance is felt.4. Lock fuel priming pump.If the engine fails to start or continues to misfire or smoke, further bleeding is necessary. With engine running, or with the use of the priming pump, loosen fuel line nuts, one at a time, several times in succession and allow fuel to run until free of air bubbles. Tighten fuel line nuts.
LOOSENING FUEL INJECTION LINE TO BLEED SYSTEMFuel Injection Equipment
When improper fuel injection is affecting engine operation, a systematic check should be made to determine the cause. The most likely cause is dirt or water in the fuel. Drain the sediment from the fuel tank. Check the fuel pressure gauge as mentioned in the topic, FUEL FILTERING SYSTEM. Replace the filters if necessary. Then prime the fuel system until clean fuel reaches the fuel injection pumps. If the fuel system is air bound, priming the system will overcome the difficulty.If the engine is running irregularly, smoking, or knocking, a fuel injection valve may not be spraying the fuel properly.Direct Injection System
The fuel system of direct injection engines is essentially the same as precombustion chamber engines. The absence of the precombustion chamber requires a different fuel nozzle and adapter. Externally the direct injection fuel nozzle resembles the precombustion chamber nozzle except it is longer in length. Nozzle testing and replacement procedure is the same as illustrated for the precombustion chamber engines, except that an extracting tool is used to remove