107691-3070 ZEXEL F 019 Z10 076 BOSCH INJECTION-PUMP ASSEMBLY f019z10076 1076913070 220008451a


107691-3070 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH F 019 Z10 076 f019z10076
ZEXEL 107691-3070 1076913070
HINO 220008451A 220008451a

Service parts 107691-3070 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 107069-1210
3. GOVERNOR 105923-0860
4. SUPPLY PUMP 105237-6260
5. AUTOM. ADVANCE MECHANIS 105681-1440
6. COUPLING PLATE 105664-2130
7. COUPLING PLATE
9. _
10. NOZZLE AND HOLDER ASSY 105160-4072
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105030-4601
14. NOZZLE 105025-0001
15. NOZZLE SET

Include in #1:

107691-3070 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 076 f019z10076
ZEXEL 107691-3070 1076913070
HINO 220008451A 220008451a


Zexel num
Bosch num
Firm num
Name
107691-3070 
107691-3071 
F 019 Z10 076 
220008451A  HINO
INJECTION-PUMP ASSEMBLY
H06C-TT * K

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8250
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.   01
PS/ACT control unit part no.   407980-2 24*
Digi switch no.   15
Direction of rotation (viewed from drive side)
Right
  R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right
  R
Injection order   1-4-2-6- 3-5
Pre-stroke mm   5.1 5.07 5.13
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   -
Rack position   11.7
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   125.5 123.5 127.5
Max. variation between cylinders %   0 -2 2
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   430 430 430
Average injection quantity mm3/st.   20.2 19.2 21.2
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(11.7)
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   125.5 124.5 126.5
Basic   *
Fixing the lever   *
Boost pressure kPa   85.3 85.3
Boost pressure mmHg   640 640
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+1.95
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   129 123 135
Fixing the lever   *
Boost pressure kPa   85.3 85.3
Boost pressure mmHg   640 640
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   (R2-2.8)
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   85 83 87
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   (R2-2.8)
Boost pressure kPa   16 14.7 17.3
Boost pressure mmHg   120 110 130
Boost compensator adjustment_02
Pump speed r/min   400 400 400
Rack position   R2(R1-0. 3)
Boost pressure kPa   72 72 72
Boost pressure mmHg   540 540 540
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   1220-50
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 107691-3070
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=AB77 BCL=(2.8)+-0.1mm
----------

Speed control lever angle

Test data 107691-3070
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=36deg+-3deg b=42deg+-5deg

Stop lever angle

Test data 107691-3070
N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)(Confirm non-injection at speed = cc.) (3)Position at the normal side lever position (back off the stop screw and move fully to the normal side). Next, screw in the stop screw and set where it contacts the stop lever. (4)Use the hole above R = dd
----------
aa=0r/min bb=1+-0.1mm cc=1460r/min dd=30mm
----------
a=34.5deg+-5deg b=46deg+-5deg

0000001301

Test data 107691-3070
(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=4deg bb=5.1+-0.03mm
----------
a=(50deg)

0000001401

Test data 107691-3070
(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 107691-3070
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107691-3070
C:Shim
----------

----------

0000001901

Test data 107691-3070
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 107691-3070
(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=1250r/min Ra=R1(11.7)+1.95mm
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0000002301 TAMPER PROOF

Test data 107691-3070
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=- N1=1250r/min Ra=(R1+2.95)+-0.1mm Q1=-
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T1 T=53.9~73.5N-m(5.5~7.5Kgf-m) T2 T=2.94~4.41N-m(0.3~0.45Kgf-m)

0000002401 TAMPER PROOF

Test data 107691-3070
(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=1430r/min R1=(12.3)+2-1mm Q1=-
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Group cross 107691-3070 ZEXEL

Hino 

107691-3070  

107691-3071 
F 019 Z10 076 
220008451A 
INJECTION-PUMP ASSEMBLY
H06C-TT
 
220008451C 
INJECTION-PUMP ASSEMBLY
H06C-TT
F 019 Z10 075 
220008451D 
INJECTION-PUMP ASSEMBLY
H06C-TT
9 400 619 816 
220008451E 
INJECTION-PUMP ASSEMBLY
H06C-TT
 
 
INJECTION-PUMP ASSEMBLY

Hino 

9 400 618 954 
220008451F 
INJECTION-PUMP ASSEMBLY
H06C-TT
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