107491-3041 ZEXEL F 019 Z10 219 BOSCH INJECTION-PUMP ASSEMBLY f019z10219 1074913041 220008391b


107491-3041 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH F 019 Z10 219 f019z10219
ZEXEL 107491-3041 1074913041
HINO 220008391B 220008391b

Service parts 107491-3041 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 107049-3080
3. GOVERNOR 105923-0820
4. SUPPLY PUMP 105237-6150
5. AUTOM. ADVANCE MECHANIS 105687-0521
6. COUPLING PLATE
7. COUPLING PLATE
9. _
10. NOZZLE AND HOLDER ASSY 105160-4051
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105030-4591
14. NOZZLE 105015-9980
15. NOZZLE SET

Include in #1:

107491-3041 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 219 f019z10219
ZEXEL 107491-3041 1074913041
HINO 220008391B 220008391b


Zexel num
Bosch num
Firm num
Name
107491-3041 
107491-3042 
F 019 Z10 219 
220008391B  HINO
INJECTION-PUMP ASSEMBLY
W04C-TM * K 14CF TICS MD-TI4 TICS

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8250
Bosch type code   1 688 901 101
Nozzle   105780-0120
Bosch type code   1 688 901 990
Nozzle holder   105780-2190
Opening pressure MPa   20.7
Opening pressure kgf/cm2   211
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   8-3-600
Overflow valve   131424-9720
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.   407910-3 03*
Selector switch no.   02
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   01
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-3-4-2
Pre-stroke mm   5.1 5.07 5.13
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-3
deg.   90 89.75 90.25
Difference between angles 2
Cal 1-4
deg.   180 179.75 180.25
Difference between angles 3
Cyl.1-2
deg.   270 269.75 270.25
Injection quantity adjustment
Adjusting point   -
Rack position   11.5
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   111 109 113
Max. variation between cylinders %   0 -3 3
Basic   *
Fixing the rack   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.1+-0.0 5
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   6+-0.5
Pump speed r/min   420 420 420
Average injection quantity mm3/st.   18.5 17 20
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   5+-0.03
PS407910-303* V   V1+0.05+ -0.01
PS407910-303* mm   5+-0.03
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Refer to items regarding the pre-stroke actuator
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.5)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   111 110 112
Basic   *
Fixing the lever   *
Boost pressure kPa   62.7 62.7
Boost pressure mmHg   470 470
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.1+-0.0 5
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.25
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   108 104 112
Fixing the lever   *
Boost pressure kPa   62.7 62.7
Boost pressure mmHg   470 470
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   3.1+-0.0 5
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.1+-0.0 5
Injection quantity adjustment_05
Adjusting point   C
Rack position   (R2-1.3)
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   55.5 53.5 57.5
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   3.1+-0.0 5
PS407910-303* V   2.25+-0. 01
PS407910-303* mm   3.1+-0.0 5
Boost compensator adjustment
Pump speed r/min   400 400 400
Rack position   (R2-1.3)
Boost pressure kPa   29.3 28 30.6
Boost pressure mmHg   220 210 230
Boost compensator adjustment_02
Pump speed r/min   400 400 400
Rack position   R2(R1-2. 2)
Boost pressure kPa   49.3 49.3 49.3
Boost pressure mmHg   370 370 370
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 -0.3 0
Timer adjustment_03
Pump speed r/min   1350-50
Advance angle deg.   -1.5 -1.8 -1.2
Remarks
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 1.95 2.05
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   5.1 5.07 5.13
Output voltage V   1.2 1 1.4
Confirmation   *
Remarks
Output voltage V1
 
_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 1.95 2.05
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   5.1 5.07 5.13
Output voltage V   1.2 1 1.4
Confirmation   *
Remarks
Output voltage V1
 
_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

Test data 107491-3041
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Stop lever's normal position setting: R1 (4)Boost compensator stroke: BCL
----------
T1=AB76 R1=(16.5)mm BCL=(1.3)+-0.1mm
----------

Speed control lever angle

Test data 107491-3041
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=51mm
----------
a=(35deg)+-3deg b=42deg+-5deg

Stop lever angle

Test data 107491-3041
N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)(Confirm non-injection at speed = cc.) (3)Rack position = dd (4)Use the hole above R = ee
----------
aa=0r/min bb=0.5+-0.3mm cc=1625r/min dd=(16.5)mm ee=40mm
----------
a=17deg+-5deg b=34deg+-5deg

0000001301

Test data 107491-3041
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=5.1+-0.03mm
----------
a=(120deg)

0000001401

Test data 107491-3041
(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

Test data 107491-3041
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107491-3041
C:Shim
----------

----------

0000001901

Test data 107491-3041
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 TAMPER PROOF

Test data 107491-3041
SW:Inner hexagonal SW14 (F): Apply thread lock adhesive . (G): Full tamper proof (H): Full boost (Full rack) (I): 0 boost 1. Mount (C) and (D) after adjusting the boost compensator. 2. Back off the load lever set screw L1 from the end face of the governor housing.. 3. Apply boost pressure and set the full load at tamper set position point aa to obtain N1, Q1 and Ra using the screw C. 4. Fix using the nut (D). 5. Next, after adjusting the stop lever, confirm the point aa. 6. Reset the load lever to the full boost rack. 7. After completion of setting, seal using the plug (E).
----------
L1=6+1mm N1=1400r/min Q1=- Ra=(R1+1.9)+-0.1mm aa=D
----------
T1 T=53.9~73.5N-m(5.5~7.5Kgf-m) T2 T=2.94~4.41N-m(0.3~0.45Kgf-m)

0000002301 TAMPER PROOF

Test data 107491-3041
(A): Rotation tamper proof (B): Full-speed setting 1. Back off the full-speed set bolt. 2. Confirm that the tamper setting position is N1, R1, Q1. 3. At that time, record the angle of the speed lever. 4. After confirming the above setting, set full speed.
----------
N1=1600r/min R1=(11)+2-1mm Q1=-
----------

0000002401 RACK SENSOR

Test data 107491-3041
R:Rack position (mm) V:Voltage (V) After installing the rack sensor, confirm the output value (VR).
----------
N1=1400r/min Ra=R1(11.5)+1.25mm VR=2.06+-0.13V(for 2V C/U) VR=3.05+-0.1V(for 3V C/U)
----------




Have questions with 107491-3041?





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