Information injection-pump assembly
BOSCH
F 019 Z10 668
f019z10668
ZEXEL
107691-2001
1076912001
Rating:
Service parts 107691-2001 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Include in #1:
107691-2001
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 668
f019z10668
ZEXEL
107691-2001
1076912001
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
131424-8520
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
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
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
5.6
5.57
5.63
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
Adjusting point
-
Rack position
10.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
77
75.4
78.6
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
7.5+-0.5
Pump speed
r/min
670
670
670
Average injection quantity
mm3/st.
9
7.5
10.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.8)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
77
76
78
Basic
*
Fixing the lever
*
Boost pressure
kPa
48
48
Boost pressure
mmHg
360
360
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.45
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
91.4
87.4
95.4
Fixing the lever
*
Boost pressure
kPa
48
48
Boost pressure
mmHg
360
360
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Injection quantity adjustment_05
Adjusting point
C
Rack position
R3(R1-0.
9)
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
37.1
33.1
41.1
Fixing the lever
*
Boost pressure
kPa
48
48
Boost pressure
mmHg
360
360
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Injection quantity adjustment_06
Adjusting point
D
Rack position
R3-0.9
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
21
17
25
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.6+-0.0
3
PS407910-303*
V
2.25+-0.
01
PS407910-303*
mm
3.6+-0.0
3
Boost compensator adjustment
Pump speed
r/min
400
400
400
Rack position
R3-0.9
Boost pressure
kPa
15.3
14
16.6
Boost pressure
mmHg
115
105
125
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Rack position
R3(R1-0.
9)
Boost pressure
kPa
34.7
34.7
34.7
Boost pressure
mmHg
260
260
260
Timer adjustment
Pump speed
r/min
1070--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1020
Advance angle
deg.
0
-0.5
0
Timer adjustment_03
Pump speed
r/min
1080
Advance angle
deg.
-1.3
-1.8
-0.8
Remarks
Finish
Finish
0000001601
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
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
5.6
5.57
5.63
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 retarding type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2.5
2.45
2.55
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
5.6
5.57
5.63
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=G34 BCL=0.9+-0.1mm
----------
----------
T1=G34 BCL=0.9+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=24deg+-5deg b=40deg+-3deg
----------
----------
a=24deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position) and confirm non-injection.
----------
aa=1670r/min bb=4.5-0.5mm
----------
a=15deg+-5deg b=38deg+-5deg
----------
aa=1670r/min bb=4.5-0.5mm
----------
a=15deg+-5deg b=38deg+-5deg
0000001301
(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=5.6+-0.03mm
----------
a=(7deg)
----------
aa=6deg bb=5.6+-0.03mm
----------
a=(7deg)
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 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.
----------
----------
----------
----------
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=1500r/min Ra=R1(10.8)+1.45mm
----------
----------
N1=1500r/min Ra=R1(10.8)+1.45mm
----------
0000002301 SPEED SENSOR
(A) Flyweight projection
(B) Pickup sensor
(c) Lock nut
Speed sensor installation
(1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L.
(This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------
----------
L=0.8~1mm
----------
Information:
COOLING SYSTEM FLOW DIAGRAM
1. Cylinder head. 2. Aftercooler. 3. Water temperature regulator housing. 4. Coolant outlet from radiator. 5. Air compressor. 6. Bypass water line. 7. Coolant outlet to aftercooler. 8. Water manifold. 9. Coolant outlet to water manifold. 10. Cylinder block. 11. Oil cooler. 12. Coolant inlet to water pump. 13. Water pump. 14. Shunt line. 15. Radiator. 16. Vent line. 17. Upper chamber. 18. Bleed tube. 19. Lower chamber.This engine has a pressurized cooling system. Coolant is circulated by a belt driven, centrifugal type water pump. A water temperature regulator, located at the left front of the cylinder head, restricts coolant flow through the radiator until the coolant reaches operating temperature.The water pump has two outlets. One outlet directs coolant through a passage in the water temperature regulator housing to the aftercooler, to lower the temperature of inlet air in the inlet manifold. The other water outlet directs coolant through a water manifold in the side of the cylinder block, to cool engine lubricating oil. Coolant flows from the water manifold around the cylinder liners, into the cylinder head and around the precombustion chambers. Both streams of water join at the water temperature regulator.The water cooled air compressor receives coolant through a tube that is connected to the water manifold in the side of the cylinder block. Coolant returns through a tube from the air compressor head to the diesel engine cylinder head.Until the coolant reaches the temperature required to open the temperature regulator, coolant bypasses the radiator and flows directly back to the water pump.When the coolant reaches the temperature required to open the temperature regulator, coolant is then directed to the radiator lower chamber.The upper chamber of the radiator receives any air in the lower chamber by way of the bleed tube. Any air in the engine is vented to the radiator upper chamber thru the vent line. The shunt line from the upper chamber to the inlet of the water pump provides for rapid filling of the system.A pressure relief cap assembly is used to control the pressure in the cooling system, and prevents loss of coolant through the radiator overflow tube.Pressurizing the cooling system serves two purposes. First, it permits safe operation at coolant temperatures higher than the normal boiling point, providing a margin of cooling for intermittent peak loads. Secondly, it prevents cavitation in the water pump, and reduces the possibility of air or steam pockets forming in the coolant passages. Proper operation of the pressure relief cap assembly is essential. A pressure relief cap allows pressure (and some water, if the cooling system is too full) to escape when the pressure in the cooling system exceeds the capacity of the pressure cap. Loss of pressure will cause steam to form when coolant temperature is above the normal boiling point.Cooling System Components
Water Pump
The centrifugal-type water pump has two seals, one prevents leakage of water and the other prevents leakage of lubricant.An opening in the bottom of the pump housing allows any