Rating:
Information injection-pump assembly
BOSCH
F 019 Z10 461
f019z10461
ZEXEL
107692-1091
1076921091
ISUZU
8943944331
8943944331
Service parts 107692-1091 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
9.
_
11.
Nozzle and Holder
8-94394-606-6
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Include in #1:
107692-1091
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 461
f019z10461
ZEXEL
107692-1091
1076921091
ISUZU
8943944331
8943944331
Zexel num
Bosch num
Firm num
Name
F 019 Z10 461
8943944331 ISUZU
INJECTION-PUMP ASSEMBLY
6HE1-XS * K 14CG TICS MD-TI6 TICS
6HE1-XS * K 14CG TICS MD-TI6 TICS
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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.
00
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
11
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
1.9
1.87
1.93
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25
Cal 1-5 deg. 60 59.75 60.25
Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25
Cal 1-3 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25
Cyl.1-2 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25
Cal 1-4 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
13.8
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
120
118.4
121.6
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
PS407980-224*
V
1.88+-0.
01
PS407980-224*
mm
3.2+-0.0
3
PS407910-303*
V
1.88+-0.
01
PS407910-303*
mm
3.2+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8.5+-0.5
Pump speed
r/min
570
570
570
Average injection quantity
mm3/st.
12.5
11.2
13.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
PS407980-224*
V
1.88+-0.
01
PS407980-224*
mm
3.2+-0.0
3
PS407910-303*
V
1.88+-0.
01
PS407910-303*
mm
3.2+-0.0
3
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.8)
Pump speed
r/min
750
750
750
Average injection quantity
mm3/st.
120
119
121
Basic
*
Fixing the lever
*
Boost pressure
kPa
62.7
62.7
Boost pressure
mmHg
470
470
PS407980-224*
V
1.88+-0.
01
PS407980-224*
mm
3.2+-0.0
3
PS407910-303*
V
1.88+-0.
01
PS407910-303*
mm
3.2+-0.0
3
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2-2.75
Boost pressure
kPa
17.3
16
18.6
Boost pressure
mmHg
130
120
140
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-0.
5)
Boost pressure
kPa
49.3
49.3
49.3
Boost pressure
mmHg
370
370
370
0000001601
CU407980-224*
*
Actuator advancing type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5
4.95
5.05
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
1.9
1.87
1.93
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 advancing type
*
Supply voltage
V
12
11.5
12.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5
4.95
5.05
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
1.9
1.87
1.93
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
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=AA11 BCL=2.75+-0.1mm
----------
----------
T1=AA11 BCL=2.75+-0.1mm
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Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt setting
----------
aa=35mm
----------
a=0deg+-5deg b=(39deg)+-3deg
----------
aa=35mm
----------
a=0deg+-5deg b=(39deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)-
(2)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection.
(3)Use the pin above R = cc
----------
aa=0r/min bb=1.5+-0.3mm cc=40mm
----------
a=12deg+-5deg b=44deg+-5deg
----------
aa=0r/min bb=1.5+-0.3mm cc=40mm
----------
a=12deg+-5deg b=44deg+-5deg
0000001301
(1)Pump vertical direction
(2)Position of flywheel's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)Pre-stroke: bb
----------
aa=19deg bb=1.9+-0.03mm
----------
a=(60deg)
----------
aa=19deg bb=1.9+-0.03mm
----------
a=(60deg)
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
----------
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0000001801
C:Shim
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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=1250r/min Ra=R1(13.8)+2.8mm
----------
----------
N1=1250r/min Ra=R1(13.8)+2.8mm
----------
0000002301 ACS
Ra = R3 (R1+2.8) mm
Rb = R3-0.15 mm
Rc = R3-0.6 mm
P1 = (89.9)+-2.7 kPa {(674)+-20 mmHg}
P2 = 78.4+-2.7 kPa {588+-20 mmHg}
P3 = 58.7+-0.7 kPa (440+-5 mmHg)
Q1=(144)cm3/1000st
Q2=(142)cm3/1000st
Q3=(136)cm3/1000st
----------
N1=1250r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3(R1+2.8)mm Rb=R3-0.15mm Rc=R3-0.6mm P1=(89.9)+-2.7kPa((674)+-20mmHg) P2=78.4+-2.7kPa(588+-20mmHg) P3=58.7+-0.7kPa(440+-5mmHg) Q1=(144)cm3/1000st Q2=(142)cm3/1000st Q3=(136)cm3/1000st
----------
N1=1250r/min L1=1.5+-0.5mm L2=37.5+-0.5mm h1=0.15mm
----------
Ra=R3(R1+2.8)mm Rb=R3-0.15mm Rc=R3-0.6mm P1=(89.9)+-2.7kPa((674)+-20mmHg) P2=78.4+-2.7kPa(588+-20mmHg) P3=58.7+-0.7kPa(440+-5mmHg) Q1=(144)cm3/1000st Q2=(142)cm3/1000st Q3=(136)cm3/1000st
0000002401 ACS
(A) Negative pressure inlet
(B) Screw
(C) Boost pressure inlet
(D) aneroid compensator body
(E) rack position aligning screw
(F) aneroid compensator spring
(G) boost compensator spring
(H) end of cover boss
(I) spring setting adjusting notch
(J) top face of lever
(K) push rod
1. Aneroid and boost compensator adjustment method
(1)When adjusting the boost compensator, remove the aneroid compensator.
(2)At full boost, select a pushrod so that the stroke is L2.
(3)Turn screw (E) and adjust the boost compensator stroke.
(4)Adjust the beginning of boost compensator operation using the notch (I).
(5)Set aneroid compensator at full boost.
(6)Turn screw (B) to adjust the clearance between the snapring and body to L1.
(7)Screw in the aneroid compensator body to adjust the beginning of aneroid compensator operation.
----------
L1=1.5+-0.5mm L2=37.5+-0.5mm
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L1=1.5+-0.5mm L2=37.5+-0.5mm
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