107492-2023 ZEXEL F 019 Z10 665 BOSCH INJECTION-PUMP ASSEMBLY f019z10665 1074922023


107492-2023 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH F 019 Z10 665 f019z10665
ZEXEL 107492-2023 1074922023

Service parts 107492-2023 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 107049-3020
3. GOVERNOR 105921-5282
4. SUPPLY PUMP 105237-4140
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE
7. COUPLING PLATE 156638-3820
9. _
10. NOZZLE AND HOLDER ASSY 105118-5381
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6(220)
13. NOZZLE-HOLDER 105048-3730
14. NOZZLE 105017-1221
15. NOZZLE SET

Include in #1:

107492-2023 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 665 f019z10665
ZEXEL 107492-2023 1074922023


Zexel num
Bosch num
Firm num
Name
107492-2023 
107492-2024 
F 019 Z10 665 
   
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   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.   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   5.6 5.57 5.63
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   12.1
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   99.5 97.9 101.1
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   7.4+-0.5
Pump speed r/min   780 780 780
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(12.1)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   99.5 98.5 100.5
Basic   *
Fixing the lever   *
Boost pressure kPa   37.3 37.3
Boost pressure mmHg   280 280
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+1.75
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   108.8 104.8 112.8
Fixing the lever   *
Boost pressure kPa   37.3 37.3
Boost pressure mmHg   280 280
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   R2+(1.3)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   93.7 89.7 97.7
Fixing the lever   *
Boost pressure kPa   37.3 37.3
Boost pressure mmHg   280 280
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   R2(R1-2. 05)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   53.6 49.6 57.6
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
Injection quantity adjustment_07
Adjusting point   E
Rack position   (R1+1.2)
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   107.3 103.3 111.3
Fixing the lever   *
Boost pressure kPa   37.3 37.3
Boost pressure mmHg   280 280
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   500 500 500
Rack position   R2(R1-2. 05)
Boost pressure kPa   12 10.7 13.3
Boost pressure mmHg   90 80 100
Boost compensator adjustment_02
Pump speed r/min   500 500 500
Rack position   R2+(1.3)
Boost pressure kPa   24 24 24
Boost pressure mmHg   180 180 180
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

Test data 107492-2023
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=G56 BCL=(1.3)+-0.1mm
----------

Speed control lever angle

Test data 107492-2023
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=22.5deg+-5deg b=(38deg)+-3deg

Stop lever angle

Test data 107492-2023
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection.
----------
aa=1600r/min bb=4.5-0.5mm
----------
a=36.5deg+-5deg b=38deg+-5deg

0000001301

Test data 107492-2023
(1)Pump vertical direction (2)Position of gear mark '3' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)Pre-stroke: bb
----------
aa=7deg bb=5.6+-0.03mm
----------
a=(130deg)

0000001401

Test data 107492-2023
(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 107492-2023
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107492-2023
C:Shim
----------

----------

0000001901

Test data 107492-2023
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.
----------

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0000002201 RACK SENSOR

Test data 107492-2023
(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(12.1)+1.75mm
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