107691-2101 ZEXEL F 019 Z10 064 BOSCH INJECTION-PUMP ASSEMBLY f019z10064 1076912101

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 064 f019z10064

ZEXEL 107691-2101 1076912101

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Service parts 107691-2101 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-0031

3. GOVERNOR 105933-0062

4. SUPPLY PUMP 105237-6210

5. AUTOM. ADVANCE MECHANIS 105681-5250

6. COUPLING PLATE 105663-0840

7. COUPLING PLATE

8. _ 159590-8120

9. _

10. NOZZLE AND HOLDER ASSY 105110-7360

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105041-3110

14. NOZZLE

15. NOZZLE SET 105019-0340

Include in #1:

107691-2101 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 064 f019z10064

ZEXEL 107691-2101 1076912101

Zexel num

Bosch num

Firm num

Name

107691-2101
107691-2102

F 019 Z10 064

INJECTION-PUMP ASSEMBLY
* K

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 131424-8420

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 5.6 5.57 5.63

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 12.2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 112 110 114

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 1.75+-0. 01

PS407980-224* mm 3.6+-0.0 5

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 700 700 700

Average injection quantity mm3/st. 10.8 9 12.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V 1.75+-0. 01

PS407980-224* mm 3.6+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.2)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 112 111 113

Basic *

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

PS407980-224* V 1.75+-0. 01

PS407980-224* mm 3.6+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+2

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 120 116 124

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

PS407980-224* V 1.75+-0. 01

PS407980-224* mm 3.6+-0.0 5

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-1.1

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2(R1-1. 4)

Boost pressure kPa 21.3 21.3 21.3

Boost pressure mmHg 160 160 160

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 3 2.5 3.5

Remarks
Finish

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 1.17 1.16 1.18

Adjustment *

_02

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 2.8 2.6 3

Confirmation *

_03

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Output voltage V 0.9

Confirmation of operating range *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Boost compensator stroke: BCL
----------
T1=AB12 BCL=1.1+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Accelerator lever
----------
aa=38mm
----------
a=26deg+-5deg b=(36deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at rack position = aa, speed = bb and confirm non-injection. (2)Use the hole above R = cc
----------
aa=0.5+-0.3mm bb=0r/min cc=40mm
----------
a=20deg+-5deg b=45deg+-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)-
----------
aa=2deg
----------
a=(0deg)

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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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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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=1350r/min Ra=R1(12.2)+2mm
----------

Information:

Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Some of the 3408E engines and 3412E engines in the above listed machines may experience hard starting or low power due to oil that is leaking past the poppet valve in the injector. The oil leakage is caused by the operating conditions at either low idle or high idle. Excessive oil leakage can reduce actuation pressure to the fuel injector. This may prevent fuel injection.Solution
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Follow the proper troubleshooting procedure for the correct engine. If the problem is not located and the symptoms that are listed above continue, remove the engine valve covers. Electrically disable the injectors. Crank the engine. Watch the spill ports of the injector for oil leakage. A small amount of oil leakage is acceptable. A continuous stream of oil may mean leakage from the poppet valve. Excessive leakage from the poppet valve may prevent fuel injection.Note: Normal oil pressure during cranking should be 5 MPa (725 psi). Oil pressure below 5 MPa (725 psi) may indicate excessive oil leakage in injectors. Do not replace the oil pump. Service personnel should replace the injectors that have a continuous flow of oil from the oil ports. Injectors that have a continuous flow of oil and injectors that are within the guidelines of warranty can be returned. Injectors that do not have a continuous flow of oil should not be replaced. Injectors that do not have a continuous flow of oil should not be returned.Note: For additional information on the operation of Hydraulic Electronic Unit Injectors HEUI, refer to CD, RENR1390.
Illustration 1 g01308874
(1) Oil drain portThe oil drain ports are located underneath the solenoid. This will direct the oil flow downward. Some oil may also leak from the rectangular slots at the side of the solenoid. Excess oil leakage will still be visible on the cylinder head.