Information injection-pump assembly
BOSCH
F 019 Z10 574
f019z10574
ZEXEL
101402-4200
1014024200
Rating:
Service parts 101402-4200 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 574
f019z10574
ZEXEL
101402-4200
1014024200
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
9.4
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
71.3
70.2
72.4
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
6.6+-0.5
Pump speed
r/min
475
475
475
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
(4)Rack difference between N = N1 and N = N2
----------
K=13 N1=1150r/min N2=800r/min
----------
----------
K=13 N1=1150r/min N2=800r/min
----------
Speed control lever angle
F:Full speed
I:Idle
D:Dead point
S:Stop
----------
----------
a=(18deg)+-5deg b=(16deg)+-5deg c=(16deg)+-5deg d=13deg+-3deg
----------
----------
a=(18deg)+-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:
start by:a) remove timing gear coverb) remove valve lifters1. Remove the turbocharger drain tube from the flywheel housing. 2. Remove two studs (1) from the flywheel housing. 3. Turn the engine with tool (B). Remove the four bolts from rear camshaft gear (2).
Tooling (A) must be used to prevent the loss of timing of the rear balance weight gear and to keep the rear camshaft gear in place when the camshaft is removed.
4. Install tooling (A) in the flywheel housing. Turn the engine until bolts (3) of tooling (A) engage in the bolt hole of the gear. The two bolts in the rear camshaft gear keep correct timing with the rear balance weight gear.5. Evenly tighten the two bolts (3) to free the gear from the camshaft. 6. Remove two bolts (4) and the thrust plate from front of the engine and camshaft. If necessary, use a driver and hammer to give more impact load on the camshaft gear as follows:a) Loosen tooling (A) to release pressure from the rear camshaft and gear.b) Remove the thrust plate from the front engine block and camshaft.c) Evenly tighten tooling (A) again.d) Use the driver and hammer to free the rear gear from the camshaft taper. 7. Remove camshaft (5) from the front of the engine block.
Be careful not to cause damage to the camshaft bearings.
Install Camshaft
1. Put clean SAE 30 engine oil on the lobes and journals of the camshaft. 2. Install camshaft (1) in the cylinder block with front camshaft gear "V" mark (3) in alignment with the idler and balance weight gear "V" mark. 3. Install thrust plate (2) and the bolts to the front of the engine that hold the camshaft in position. 4. Loosen bolts (5) of tooling (A) from the rear camshaft gear (4) to make alignment of camshaft dowel with the dowel hole in the gear. Install the gear on the camshaft. 5. Install one bolt (6) to hold the gear to the camshaft. Remove tooling (A) from the camshaft gear and flywheel housing.6. Turn the engine with tool (B) and install the remainder of the bolts that hold the gear to the camshaft. Tighten the bolts to a torque of 20 3 lb.ft. (25 4 N m).7. Install the two studs and the turbocharger drain tube to the flywheel housing.end by:a) install valve liftersb) install timing gear cover
Tooling (A) must be used to prevent the loss of timing of the rear balance weight gear and to keep the rear camshaft gear in place when the camshaft is removed.
4. Install tooling (A) in the flywheel housing. Turn the engine until bolts (3) of tooling (A) engage in the bolt hole of the gear. The two bolts in the rear camshaft gear keep correct timing with the rear balance weight gear.5. Evenly tighten the two bolts (3) to free the gear from the camshaft. 6. Remove two bolts (4) and the thrust plate from front of the engine and camshaft. If necessary, use a driver and hammer to give more impact load on the camshaft gear as follows:a) Loosen tooling (A) to release pressure from the rear camshaft and gear.b) Remove the thrust plate from the front engine block and camshaft.c) Evenly tighten tooling (A) again.d) Use the driver and hammer to free the rear gear from the camshaft taper. 7. Remove camshaft (5) from the front of the engine block.
Be careful not to cause damage to the camshaft bearings.
Install Camshaft
1. Put clean SAE 30 engine oil on the lobes and journals of the camshaft. 2. Install camshaft (1) in the cylinder block with front camshaft gear "V" mark (3) in alignment with the idler and balance weight gear "V" mark. 3. Install thrust plate (2) and the bolts to the front of the engine that hold the camshaft in position. 4. Loosen bolts (5) of tooling (A) from the rear camshaft gear (4) to make alignment of camshaft dowel with the dowel hole in the gear. Install the gear on the camshaft. 5. Install one bolt (6) to hold the gear to the camshaft. Remove tooling (A) from the camshaft gear and flywheel housing.6. Turn the engine with tool (B) and install the remainder of the bolts that hold the gear to the camshaft. Tighten the bolts to a torque of 20 3 lb.ft. (25 4 N m).7. Install the two studs and the turbocharger drain tube to the flywheel housing.end by:a) install valve liftersb) install timing gear cover