Information injection-pump assembly
BOSCH
F 019 Z10 890
f019z10890
ZEXEL
106872-3141
1068723141
HINO
220007121A
220007121a
Rating:
Service parts 106872-3141 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
236002271A
12.
Open Pre:MPa(Kqf/cm2)
15.7(160)/21.6(220)
15.
NOZZLE SET
Include in #1:
106872-3141
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 890
f019z10890
ZEXEL
106872-3141
1068723141
HINO
220007121A
220007121a
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
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
26
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
6.4
6.37
6.43
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
9.7
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
157
155
159
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Injection quantity adjustment_02
Adjusting point
B
Rack position
9.05
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
142.9
139.9
145.9
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_03
Adjusting point
C
Rack position
10.1
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
163
160
166
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_04
Adjusting point
F
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
126
126
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_05
Adjusting point
G
Rack position
5+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
8
5
11
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Injection quantity adjustment_06
Adjusting point
H
Rack position
10.6+-0.
1
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
195.8
190.8
200.8
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Rack limit
*
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
8.25
Boost pressure
kPa
4
1.3
6.7
Boost pressure
mmHg
30
10
50
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
9.05
Boost pressure
kPa
13.3
13.3
13.3
Boost pressure
mmHg
100
100
100
0000001601
Pre-stroke
mm
6.4
6.37
6.43
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
5
4.5
5.5
Remarks
When the eccentric pin is tightened
When the eccentric pin is tightened
_03
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
4
3.95
4.05
Output voltage
V
2.62
2.61
2.63
Adjustment
*
_04
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
6.4
6.37
6.43
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_05
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
3.4
Output voltage
V
3
2.98
3
Confirmation
*
_06
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)Tolerance for racks not indicated: +-0.05mm.
(2)RACK LIMIT: RAL
(3)Damper spring setting
----------
RAL=10.6+-0.1mm
----------
----------
RAL=10.6+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=16deg+-5deg
----------
----------
a=16deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=20deg+-5deg b=28deg+-3deg
----------
----------
a=20deg+-5deg b=28deg+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
(3)Free (at delivery)
(4)Set the stopper bolt (apply red paint).
----------
aa=11mm bb=2.3-0.5mm
----------
a=24deg+-5deg b=(24deg)+-5deg c=(40deg)
----------
aa=11mm bb=2.3-0.5mm
----------
a=24deg+-5deg b=(24deg)+-5deg c=(40deg)
0000001301
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)Pre-stroke: aa
(4)-
----------
aa=6.4+-0.03mm
----------
a=(80deg)
----------
aa=6.4+-0.03mm
----------
a=(80deg)
0000001901
(A): Pre-stroke actuator
(B): Stamp housings A and B at the same time.
(C): Stamping range
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 limit adjustment
(1)Mount the joint (B).
(2)Select the shim (D) so that the rack limit's rack position is obtained at that time.
(3)Install the rod (E) to the block (C).
The distance between the pump end face and the rod (E) at rack limit must be L.
2. Rack sensor adjustment (-0020)
(1)Screw in the bobbin (A) until it contacts the joint (B).
(2)Fix the speed control lever at the full side.
(3)Set at speed N.
(4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.)
(5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(6)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)
----------
L=38-0.2mm N=900r/min Ra=(10.1)mm
----------
----------
L=38-0.2mm N=900r/min Ra=(10.1)mm
----------
0000002301 GOVERNOR TORQUE CONTROL
Dr:Torque control stroke
(A): Without torque control spring capsule
1. Adjustment procedures
(1)Procedure is the same as that for the RFD (former type), except that the positive torque control stroke must be determined at the full lever setting.
2. Procedures for adjustment
(1)Remove the torque control spring capsule.
(2)Operate the pump at approximately N1. (End of idling spring operation < N1.)
(3)Tilt the lever to the full side.
(4)Set so that R = RF.
(5)Increase the speed by pushing in the screw (attached to the bracket on the rear of the tension lever) through the adjusting window.
(6)Adjust so that the torque control stroke Dr1 can be obtained.
(7)Align N2 and N3 with the torque control spring capsule.
3. Final confirmation
(1)After final confirmation, temporarily set the load lever to N = N1, R = idling position.
(2)From this condition, increase speed to N = N4.
(3)Confirm that positive torque control stroke is Dr2.
----------
N1=500r/min N2=- N3=- N4=1100r/min RF=9.05mm Dr1=1.05mm Dr2=0+0.3mm
----------
----------
N1=500r/min N2=- N3=- N4=1100r/min RF=9.05mm Dr1=1.05mm Dr2=0+0.3mm
----------
Information:
Fuel Tank Drain
Fuel tank drains are used to drain water and sediment from the fuel tank daily. The drain must be located on the lowest part of the fuel tank where the containments collect.Note: Daily draining of water and sediment from the fuel tank has been a standard maintenance requirement for decades.Advanced Tank Breather Filter
Preventing short fuel system life by keeping dust from entering the fuel tank.Water Separators
Water separators are required to remove large quantities of latent water from the fuel.Primary Fuel Filters
Primary fuel filters are required to remove large abrasives from the fuel supply and prevent premature clogging of the 4-micron secondary filters from excessive debris.Secondary Fuel Filters
Series filtration more than doubles wear life over single filtration.Electronic Unit Injectors (EUI)
An adequate fuel supply pressure is essential to prevent cavitation of internal injector components due to incomplete fuel fill.Major Factors Which Negatively Affect Fuel System Wear
Abrasive Contaminants
Increased injection pressure acting on the same level of abrasive contaminants in the fuel results in accelerated injector abrasive wear. This abrasive wear cannot be eliminated by using improved materials or processes. Abrasive wear only can be reduced by removing abrasives from the fuel. Solution
Single or series High Efficiency fuel filters and/or bulk fuel filter/water coalescer.Water in Fuel
An excessive amount of latent water in the fuel is a key cause of injector failure. Water has inadequate film strength to prevent metal-to-metal contact between the plunger and barrel, resulting in plunger scuffing or seizure. Water can be effectively by the use and regular maintenance of a water separator or bulk fuel filter/water coalescer. Removal of excess latent water is essential to prevent scuffing with the upcoming injection pressure increases and subsequent hydraulic loading of internal injector parts.Solution
Proper maintenance of fuel tank drains, water separators and/or use of a bulk fuel filter/water coalescer.Excessive Fuel Temperature
Increasing fuel temperatures reduces fuel viscosity and resultant fuel film strength. Reduced film strength increases the probability of injector plunger and barrel scuffing or seizure. Limiting the maximum fuel temperature will become even more critical with the increase of use if low sulfur fuel which has a lower film strength and common rail fuel systems which run elevated fuel temperatures. Fuel temperatures also play in diesel and biodiesel fuel degradation.Solution
Properly maintain fuel filters and fuel coolers where needed. Ensure proper consideration for materials used in fuel coolers as zinc, copper, lead, and tin can have adverse effects on fuel degradation.Customer Maintenance Practices
Fuel system performance, sophistication, and complexity continue to increase at a rapid pace. It is more important than ever for the user to maintain fuel filters in order to prevent filter restriction and the problems caused by low fuel pressure. It is also important to use quality Advanced Efficiency filters in order to trap and hold microscopic abrasive debris, which causes accelerated wear in modern fuel systems.C7 and C9 HEUI Fuel System Diagram
Note: The following illustration identifies components that may be included in many different arrangements. Refer to the Service Information System (SIS) for the correct components for the
Fuel tank drains are used to drain water and sediment from the fuel tank daily. The drain must be located on the lowest part of the fuel tank where the containments collect.Note: Daily draining of water and sediment from the fuel tank has been a standard maintenance requirement for decades.Advanced Tank Breather Filter
Preventing short fuel system life by keeping dust from entering the fuel tank.Water Separators
Water separators are required to remove large quantities of latent water from the fuel.Primary Fuel Filters
Primary fuel filters are required to remove large abrasives from the fuel supply and prevent premature clogging of the 4-micron secondary filters from excessive debris.Secondary Fuel Filters
Series filtration more than doubles wear life over single filtration.Electronic Unit Injectors (EUI)
An adequate fuel supply pressure is essential to prevent cavitation of internal injector components due to incomplete fuel fill.Major Factors Which Negatively Affect Fuel System Wear
Abrasive Contaminants
Increased injection pressure acting on the same level of abrasive contaminants in the fuel results in accelerated injector abrasive wear. This abrasive wear cannot be eliminated by using improved materials or processes. Abrasive wear only can be reduced by removing abrasives from the fuel. Solution
Single or series High Efficiency fuel filters and/or bulk fuel filter/water coalescer.Water in Fuel
An excessive amount of latent water in the fuel is a key cause of injector failure. Water has inadequate film strength to prevent metal-to-metal contact between the plunger and barrel, resulting in plunger scuffing or seizure. Water can be effectively by the use and regular maintenance of a water separator or bulk fuel filter/water coalescer. Removal of excess latent water is essential to prevent scuffing with the upcoming injection pressure increases and subsequent hydraulic loading of internal injector parts.Solution
Proper maintenance of fuel tank drains, water separators and/or use of a bulk fuel filter/water coalescer.Excessive Fuel Temperature
Increasing fuel temperatures reduces fuel viscosity and resultant fuel film strength. Reduced film strength increases the probability of injector plunger and barrel scuffing or seizure. Limiting the maximum fuel temperature will become even more critical with the increase of use if low sulfur fuel which has a lower film strength and common rail fuel systems which run elevated fuel temperatures. Fuel temperatures also play in diesel and biodiesel fuel degradation.Solution
Properly maintain fuel filters and fuel coolers where needed. Ensure proper consideration for materials used in fuel coolers as zinc, copper, lead, and tin can have adverse effects on fuel degradation.Customer Maintenance Practices
Fuel system performance, sophistication, and complexity continue to increase at a rapid pace. It is more important than ever for the user to maintain fuel filters in order to prevent filter restriction and the problems caused by low fuel pressure. It is also important to use quality Advanced Efficiency filters in order to trap and hold microscopic abrasive debris, which causes accelerated wear in modern fuel systems.C7 and C9 HEUI Fuel System Diagram
Note: The following illustration identifies components that may be included in many different arrangements. Refer to the Service Information System (SIS) for the correct components for the