Information injection-pump assembly
BOSCH
F 019 Z10 325
f019z10325
ZEXEL
101402-4151
1014024151
ISUZU
8970314861
8970314861
Rating:
Service parts 101402-4151 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97013-319-1
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 325
f019z10325
ZEXEL
101402-4151
1014024151
ISUZU
8970314861
8970314861
Zexel num
Bosch num
Firm num
Name
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 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-4920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.4
3.35
3.45
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
A
Rack position
9.8
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
88.6
87.5
89.7
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
10.4
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
83.5
81.5
85.5
Max. variation between cylinders
%
0
-4
4
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
-
Rack position
6.7+-0.5
Pump speed
r/min
440
440
440
Average injection quantity
mm3/st.
8.8
7.4
10.2
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Set idle sub-spring
(3)Main spring setting
----------
K=7
----------
----------
K=7
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
D:Dead point
----------
----------
a=(23deg)+-5deg b=(16deg)+-5deg c=(16deg)+-5deg d=13deg+-3deg
----------
----------
a=(23deg)+-5deg b=(16deg)+-5deg c=(16deg)+-5deg d=13deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=6deg+-5deg b=46deg+-5deg
----------
----------
a=6deg+-5deg b=46deg+-5deg
0000001501 LEVER
1. Variable lever adjustment
(1)Fix lever B in the idle position using the bolts C and D.
(2)Temporarily fix lever A in center of long hole.
(3)Set the dead point position temporarily and measure the lever angle.
(4)After idle adjustment, loosen the full side stopper bolt D.
(5)Move lever A in full speed direction.
(6)Fix the bolt D at the full speed position.
(7)Fix lever A using bolt E.
(8)(G) Lock using bolt.
(9)Finally, measure the lever angle and set the idle stopper bolt (C) stop position.
----------
----------
----------
----------
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=18deg
----------
a=(90deg)
----------
aa=18deg
----------
a=(90deg)
Information:
1. Loosen bolt (2) on belt tightener bracket (1).2. Remove the belts from the idler pulley.3. Remove bolt (3) that holds the bracket to the engine cover. Remove the idler pulley and the bracket as a unit.Install Belt Tightener Idler Pulley
1. Put the pulley and bracket as a unit in position on the engine cover.2. Install the bolts loosely that hold the pulley and bracket to the engine cover.3. Install the belts on the pulleys and make belt adjustment so movement (deflection) is 7/8 in. (22.2 mm) under 25 lb. (110 N) force halfway between pulleys.4. Tighten the 5/8" diameter bolt on the belt tightener bracket to a torque of 75 10 lb.ft. (100 14 N m). Tighten the 1/2" diameter bolt to a torque of 40 5 lb.ft. (55 7 N m).Disassemble Belt Tightener Idler Pulley
start by: a) remove belt tightener idler pulley 1. Remove bolts (1) and cover (2). 2. Remove bolts (5) and washer (6) from bracket (3).3. Lift pulley (4) from the bracket. 4. Remove O-ring seal (7), bearing (11) and spacer (8) from the pulley.5. Remove spacer (10), lip type seal (12) and bearing (9) from the rear of the pulley.Assemble Belt Tightener Idler Pulley
1. Install the bearing in the rear of pulley (1) with tooling (A).2. Put 5P960 Multipurpose Grease on the lips of the seal. Install the lip type seal with the lip toward the rear surface of the pulley with tooling (B).3. Install the spacer in the pulley. Install the spacer in the O-ring seal until it makes contact with the bearing. 4. Install the spacer from the front side of the pulley. Install bearing (2) with tooling (A) in the pulley (1).5. Put O-ring seal (3) in position on the pulley. Put the pulley in position on pulley bracket shaft (4).6. Install the washer and the bolts that hold the pulley on the bracket. Install the cover and the bolts on the pulley.7. Fill pulley with 5P960 Multipurpose Grease.end by:a) install belt tightener idler pulley
1. Put the pulley and bracket as a unit in position on the engine cover.2. Install the bolts loosely that hold the pulley and bracket to the engine cover.3. Install the belts on the pulleys and make belt adjustment so movement (deflection) is 7/8 in. (22.2 mm) under 25 lb. (110 N) force halfway between pulleys.4. Tighten the 5/8" diameter bolt on the belt tightener bracket to a torque of 75 10 lb.ft. (100 14 N m). Tighten the 1/2" diameter bolt to a torque of 40 5 lb.ft. (55 7 N m).Disassemble Belt Tightener Idler Pulley
start by: a) remove belt tightener idler pulley 1. Remove bolts (1) and cover (2). 2. Remove bolts (5) and washer (6) from bracket (3).3. Lift pulley (4) from the bracket. 4. Remove O-ring seal (7), bearing (11) and spacer (8) from the pulley.5. Remove spacer (10), lip type seal (12) and bearing (9) from the rear of the pulley.Assemble Belt Tightener Idler Pulley
1. Install the bearing in the rear of pulley (1) with tooling (A).2. Put 5P960 Multipurpose Grease on the lips of the seal. Install the lip type seal with the lip toward the rear surface of the pulley with tooling (B).3. Install the spacer in the pulley. Install the spacer in the O-ring seal until it makes contact with the bearing. 4. Install the spacer from the front side of the pulley. Install bearing (2) with tooling (A) in the pulley (1).5. Put O-ring seal (3) in position on the pulley. Put the pulley in position on pulley bracket shaft (4).6. Install the washer and the bolts that hold the pulley on the bracket. Install the cover and the bolts on the pulley.7. Fill pulley with 5P960 Multipurpose Grease.end by:a) install belt tightener idler pulley