106672-3581 ZEXEL F 019 Z10 869 BOSCH INJECTION-PUMP ASSEMBLY f019z10869 1066723581 220006921a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 019 Z10 869 f019z10869

ZEXEL 106672-3581 1066723581

HINO 220006921A 220006921a

Service parts 106672-3581 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106061-5971

3. GOVERNOR 105489-2712

4. SUPPLY PUMP 105237-1960

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-0740

7. COUPLING PLATE 156638-1220

8. _ 159590-2520

9. _

10. NOZZLE AND HOLDER ASSY 105101-7191

11. Nozzle and Holder 236002260A

12. Open Pre:MPa(Kqf/cm2) 16.7(170)/23.5(240)

13. NOZZLE-HOLDER 105031-7251

14. NOZZLE

15. NOZZLE SET 105019-0000

Include in #1:

106672-3581 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 869 f019z10869

ZEXEL 106672-3581 1066723581

HINO 220006921A 220006921a

Zexel num

Bosch num

Firm num

Name

106672-3581
106672-3582

F 019 Z10 869

220006921A HINO

INJECTION-PUMP ASSEMBLY
K13C-TC * 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 134424-1420

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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. 31

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 6.4 6.37 6.43

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

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

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

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

Injection quantity adjustment

Adjusting point A

Rack position 10.9

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 199.2 197.2 201.2

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

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

Injection quantity adjustment_02

Adjusting point B

Rack position 11.15

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 214.9 208.9 220.9

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Injection quantity adjustment_03

Adjusting point F

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 215.3 210.3 220.3

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

Rack limit *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Injection quantity adjustment_04

Adjusting point G

Rack position 4.9+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 10 7 13

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

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 8.7

Boost pressure kPa 3.3 3.3 5.3

Boost pressure mmHg 25 25 40

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 10.65

Boost pressure kPa 30.7 30.7 30.7

Boost pressure mmHg 230 230 230

0000001601

Pre-stroke mm 6.4 6.37 6.43

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 8.5 8.45 8.55

Remarks
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 2.45 2.44 2.46

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

_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 (3)Damper spring setting
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Speed control lever angle

F:Full speed
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a=15.5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=25deg+-5deg b=31.5deg+-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). (5)(Actual measurement)
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aa=12.9mm bb=2.4-0.5mm
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a=44deg+-5deg b=35deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
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aa=6.4+-0.03mm
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a=(0deg)

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)
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L=38-0.2mm N=850r/min Ra=(11.15)mm
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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.
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N1=500r/min N2=- N3=- N4=1000r/min RF=10.65mm Dr1=0.5mm Dr2=0+0.3mm
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