Information injection-pump assembly
ZEXEL
107692-1320
1076921320
ISUZU
8943920090
8943920090
Rating:
Service parts 107692-1320 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:
107692-1320
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
107692-1320
1076921320
ISUZU
8943920090
8943920090
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.
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
5.1
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
Adjusting point
-
Rack position
13.1
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
102
100.4
103.6
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-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
420
420
420
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
5+-0.03
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(13.1)
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
102
101
103
Basic
*
Fixing the lever
*
Boost pressure
kPa
60
60
Boost pressure
mmHg
450
450
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-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 retarding type
*
Supply voltage
V
24
23.5
24.5
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
24
23.5
24.5
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
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:
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)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=2deg+-5deg b=34deg+-3deg
----------
aa=35mm
----------
a=2deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
(2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection.
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=12deg+-5deg b=44deg+-5deg
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
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=4deg bb=5.1+-0.03mm
----------
a=(50deg)
----------
aa=4deg bb=5.1+-0.03mm
----------
a=(50deg)
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.
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----------
----------
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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.
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----------
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0000002201 RACK SENSOR
G:Red paint
H:Pump end face
P/N: part number of suitable shim
(1)Threaded type rack block
(2)Welded type rack block
Rack sensor adjustment
1. Threaded type rack sensor (-5*20, P type, no TICS rack limit).
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the pump lever.
(3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1.
(4)Fix using the nut (F).
(5)Affix the caution plate to the upper part of the joint (B).
(6)Apply (G) at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the end surface of the pump (H) and the joint (B)
2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads.
Screw in to the end from (the position where the bobbin (A) is rotated 9 turns).
Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(13.1)+2.35mm N1=1250r/min V1=3+-0.01V
----------
----------
Ra=R1(13.1)+2.35mm N1=1250r/min V1=3+-0.01V
----------
0000002301 ACS
(A) Set screw
(B) Push rod 1
(C) Push rod 2
(D) Lever
1. Aneroid compensator unit adjustment
(1)Screw in (A) to obtain L1.
(2)Select C so that dimension L2 can be obtained.
2. Adjustment when mounting the governor.
(1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position.
(2)Set to full boost.
(3)Screw in the aneroid compensator body to obtain the performance shown in the graph above.
(4)As there is hysterisis, measure when the absolute pressure drops.
(5)Hysterisis must not exceed rack position = h1.
----------
N1=1250r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3(R1+2.35)mm Rb=R3-0.15mm Rc=R3-0.5mm P1=(89.9)+-2.7kPa((674)+-20mmHg) P2=84.6+-2.7kPa(635+-20mmHg) P3=70.1+-0.7kPa(526+-5mmHg) Q1=(112)cm3/1000st Q2=(110)cm3/1000st Q3=(106)+-2cm3/1000st
----------
N1=1250r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3(R1+2.35)mm Rb=R3-0.15mm Rc=R3-0.5mm P1=(89.9)+-2.7kPa((674)+-20mmHg) P2=84.6+-2.7kPa(635+-20mmHg) P3=70.1+-0.7kPa(526+-5mmHg) Q1=(112)cm3/1000st Q2=(110)cm3/1000st Q3=(106)+-2cm3/1000st
Information:
You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.This maintenance is to be performed at the interval specified in the Maintenance Schedule for the engine being maintained.Before proceeding with 125 Service Hour maintenance, first perform previous maintenance requirements.Clutch (If Equipped)
Refer to the Instruction Plate on your clutch for the correct lubrication information.Lubricate Shift Collar Bearings
Instruction PlateLubricate the shift collar fittings with one or two grease gun shots each with MPGL or 2S3230 grease. Do not over grease.Lubricate Shift Lever Bearings
Refer to the Instruction Plate on the clutch for lubrication information.Some earlier clutches have pilot bearing fittings that need lubrication, whereas the later clutches have pilot bearings that are sealed for life.Lubricate the clutch shift lever bearings, pilot bearing and main shaft bearing (if equipped). Lubricate one fitting on top-rear of housing. Lubricate one fitting at the end of shaft. Refer to Instruction Plate on your clutch for correct lubrication information.Check/Adjust
If the clutch is damaged to the point of burst failure, expelled pieces can cause personal injury to anyone in the immediate area. Proper safeguards must be followed to prevent accidents.Do NOT operate the engine with Instruction Plate cover removed from the clutch. Personal injury may result.
While engaging the clutch to pick up the load, check the clutch adjustment. The clutch should engage with a firm push of the lever and a distinct snap. If the engagement is "soft" or slow, adjust the clutch.When clutch lever is disengaged, the hand lever must fall behind the vertical position. If the clutch slips, overheats, or operating lever disengages, clutch adjustment is necessary.1. Stop the engine and remove the clutch inspection cover.2. Rotate the clutch manually until the lock pin (engaged in the locking ring) is visible.3. Pull the lock pin out and rotate the locking ring clockwise (CW) until the lock pin slips or pops into the next notch. Turn adjusting ring CW to increase engagement torque and CCW to decrease engagement torque.4. Test the clutch adjustment. To test the clutch adjustment, engage clutch with a torque wrench to turn adjusting ring so that 296 to 393 N m (218 to 289 lb ft)torque or 636 90 N (143 20 lb) force at 541 mm (21.3 inches) length on lever is required to engage the clutch. If torque is still low, rotate the locking ring (CW) until lock pin slips into next notch. If the adjustment is too tight, turn the locking ring back (CCW) one to the previous notch.5. Install cover plate after adjustment is completed.
Refer to the Instruction Plate on your clutch for the correct lubrication information.Lubricate Shift Collar Bearings
Instruction PlateLubricate the shift collar fittings with one or two grease gun shots each with MPGL or 2S3230 grease. Do not over grease.Lubricate Shift Lever Bearings
Refer to the Instruction Plate on the clutch for lubrication information.Some earlier clutches have pilot bearing fittings that need lubrication, whereas the later clutches have pilot bearings that are sealed for life.Lubricate the clutch shift lever bearings, pilot bearing and main shaft bearing (if equipped). Lubricate one fitting on top-rear of housing. Lubricate one fitting at the end of shaft. Refer to Instruction Plate on your clutch for correct lubrication information.Check/Adjust
If the clutch is damaged to the point of burst failure, expelled pieces can cause personal injury to anyone in the immediate area. Proper safeguards must be followed to prevent accidents.Do NOT operate the engine with Instruction Plate cover removed from the clutch. Personal injury may result.
While engaging the clutch to pick up the load, check the clutch adjustment. The clutch should engage with a firm push of the lever and a distinct snap. If the engagement is "soft" or slow, adjust the clutch.When clutch lever is disengaged, the hand lever must fall behind the vertical position. If the clutch slips, overheats, or operating lever disengages, clutch adjustment is necessary.1. Stop the engine and remove the clutch inspection cover.2. Rotate the clutch manually until the lock pin (engaged in the locking ring) is visible.3. Pull the lock pin out and rotate the locking ring clockwise (CW) until the lock pin slips or pops into the next notch. Turn adjusting ring CW to increase engagement torque and CCW to decrease engagement torque.4. Test the clutch adjustment. To test the clutch adjustment, engage clutch with a torque wrench to turn adjusting ring so that 296 to 393 N m (218 to 289 lb ft)torque or 636 90 N (143 20 lb) force at 541 mm (21.3 inches) length on lever is required to engage the clutch. If torque is still low, rotate the locking ring (CW) until lock pin slips into next notch. If the adjustment is too tight, turn the locking ring back (CCW) one to the previous notch.5. Install cover plate after adjustment is completed.