Information injection-pump assembly
BOSCH
F 019 Z10 648
f019z10648
ZEXEL
106871-8800
1068718800
HINO
220007280A
220007280a
Rating:
Service parts 106871-8800 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
236001651A
12.
Open Pre:MPa(Kqf/cm2)
15.7(160)/21.6(220)
15.
NOZZLE SET
Include in #1:
106871-8800
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 648
f019z10648
ZEXEL
106871-8800
1068718800
HINO
220007280A
220007280a
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
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
134424-0820
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
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
1-8-6-2-
7-5-4-3
Pre-stroke
mm
4.8
4.74
4.8
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25
Cal 1-6 deg. 90 89.75 90.25
Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25
Cyl.1-2 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25
Cal 1-7 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25
Cal 1-5 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25
Cal 1-4 deg. 270 269.75 270.25
Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25
Cal 1-3 deg. 315 314.75 315.25
Injection quantity adjustment
Adjusting point
A
Rack position
9.5
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
143.6
141.6
145.6
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.8
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
141.1
138.1
144.1
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
9.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
143.4
140.4
146.4
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
9.5
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
148.5
142.5
154.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
9.1
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
123.4
117.4
129.4
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
F
Rack position
4.2+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
9.6
6.6
12.6
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Timer adjustment
Pump speed
r/min
900
Advance angle
deg.
1.7
1.4
2
Load
3/4
Timer adjustment_02
Pump speed
r/min
1060
Advance angle
deg.
4.75
4.45
5.05
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Excess fuel setting for starting: SXL
(5)Set the damper spring (after setting the idle spring).
----------
RT=0.8 TH=2.7mm SXL=10.7+-0.1mm
----------
----------
RT=0.8 TH=2.7mm SXL=10.7+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=14deg+-5deg
----------
----------
a=14deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=42mm
----------
a=39deg+-5deg b=46deg+-3deg
----------
aa=42mm
----------
a=39deg+-5deg b=46deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=46deg+-5deg b=64deg+-5deg
----------
----------
a=46deg+-5deg b=64deg+-5deg
0000001501 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=1070r/min Ra=9.8mm
----------
----------
N1=1070r/min Ra=9.8mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(80deg)
----------
----------
a=(80deg)
Information:
Install Water Pump
1. Put the gasket and water pump (1) in position in the timing gear cover. 2. Install the pointer and bolts to hold the water pump.3. Put the vee belts in position on the engine.4. Use a belt tension gauge such as Borroughs Tool Company Part No. BT-33-72C or an equivalent and make an adjustment of the vee belts. Tighten new belts until the gauge indication is 120 5. Operate the engine at high idle for a minimum of 30 minutes after Step 5. Make another adjustment of the belt tension. The correct gauge indication for used belts is 90 10. Tighten the bolts that hold the alternator.5. Fill the cooling system with coolant to the correct level.Disassemble Water Pump
a) remove water pump1. Hold the pump shaft in a vise as shown and remove the bolt and pulley (1). 2. Use tooling (A) and a press to remove the shaft, seal and impeller from housing (2) as shown.
The press must have a guard. The guard has been removed for photo illustration.
3. Remove bearing (3) from housing (2). 4. Remove spacer (4) from housing (2). 5. Use tool (B) to remove ring (5) from housing (2). Remove bearing (6) from housing (2).6. Use a press and tool (C) to remove the shaft and seal assembly from impeller (7) as shown. 7. Install the seal assembly and shaft in housing (2) as shown. Use a press and tool (C) to remove the shaft from the seal assembly. Assemble Water Pump
1 Install bearing (1) in housing (3). Use tool (A) to install ring (2) that holds bearing (1) in position. 2 Install spacer (4) in housing (3). 3 Make sure the outside diameter of bearing (5) and the bore in housing (3) are clean and dry. Install bearing (5) in housing (3). Fill the chamber area between the housing and outside diameter of bearing (5) with 7M7456 Bearing Mount. Remove the excess bearing mount from the housing. 4. Turn the pump housing over and make sure that the bores in the bearings and spacer are in alignment. Install the shaft through the bearings from the impeller side of the housing. The shaft to bearing clearance can be 0.018 mm (.0007 in.) loose to 0.008 mm (.0003 in.) tight. If it is necessary to use a press to install the shaft, make sure the inner races of the bearings have support. 5. Install pulley (6) on the shaft and tighten the bolt to a torque of 75 7 N m (55 5 lb.ft.). 6. Put a new seal assembly (7) on the shaft as shown.7. Use tool (B) and a press to install the seal assembly in housing (3). Do not use a hammer to install the seal. 8. Put tool (D) between impeller (8) and the pump housing.9. Use a press and tool (C) to install impeller (8) on the shaft until tool (D) can just be moved between the housing and impeller. 10. If
1. Put the gasket and water pump (1) in position in the timing gear cover. 2. Install the pointer and bolts to hold the water pump.3. Put the vee belts in position on the engine.4. Use a belt tension gauge such as Borroughs Tool Company Part No. BT-33-72C or an equivalent and make an adjustment of the vee belts. Tighten new belts until the gauge indication is 120 5. Operate the engine at high idle for a minimum of 30 minutes after Step 5. Make another adjustment of the belt tension. The correct gauge indication for used belts is 90 10. Tighten the bolts that hold the alternator.5. Fill the cooling system with coolant to the correct level.Disassemble Water Pump
a) remove water pump1. Hold the pump shaft in a vise as shown and remove the bolt and pulley (1). 2. Use tooling (A) and a press to remove the shaft, seal and impeller from housing (2) as shown.
The press must have a guard. The guard has been removed for photo illustration.
3. Remove bearing (3) from housing (2). 4. Remove spacer (4) from housing (2). 5. Use tool (B) to remove ring (5) from housing (2). Remove bearing (6) from housing (2).6. Use a press and tool (C) to remove the shaft and seal assembly from impeller (7) as shown. 7. Install the seal assembly and shaft in housing (2) as shown. Use a press and tool (C) to remove the shaft from the seal assembly. Assemble Water Pump
1 Install bearing (1) in housing (3). Use tool (A) to install ring (2) that holds bearing (1) in position. 2 Install spacer (4) in housing (3). 3 Make sure the outside diameter of bearing (5) and the bore in housing (3) are clean and dry. Install bearing (5) in housing (3). Fill the chamber area between the housing and outside diameter of bearing (5) with 7M7456 Bearing Mount. Remove the excess bearing mount from the housing. 4. Turn the pump housing over and make sure that the bores in the bearings and spacer are in alignment. Install the shaft through the bearings from the impeller side of the housing. The shaft to bearing clearance can be 0.018 mm (.0007 in.) loose to 0.008 mm (.0003 in.) tight. If it is necessary to use a press to install the shaft, make sure the inner races of the bearings have support. 5. Install pulley (6) on the shaft and tighten the bolt to a torque of 75 7 N m (55 5 lb.ft.). 6. Put a new seal assembly (7) on the shaft as shown.7. Use tool (B) and a press to install the seal assembly in housing (3). Do not use a hammer to install the seal. 8. Put tool (D) between impeller (8) and the pump housing.9. Use a press and tool (C) to install impeller (8) on the shaft until tool (D) can just be moved between the housing and impeller. 10. If