Information injection-pump assembly
BOSCH
F 019 Z10 476
f019z10476
ZEXEL
101402-4220
1014024220
ISUZU
8970497810
8970497810
Rating:
Service parts 101402-4220 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97030-285-1
12.
Open Pre:MPa(Kqf/cm2)
14.7(150)
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 476
f019z10476
ZEXEL
101402-4220
1014024220
ISUZU
8970497810
8970497810
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
3.6
3.55
3.65
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
10.1
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
66.4
65.3
67.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.7+-0.5
Pump speed
r/min
475
475
475
Average injection quantity
mm3/st.
10
8.6
11.4
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
(1)Stopper bolt setting
----------
----------
a=(2deg)+-5deg b=(19deg)+-5deg c=35deg+-3deg
----------
----------
a=(2deg)+-5deg b=(19deg)+-5deg c=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=19deg+-5deg b=53deg+-5deg
----------
----------
a=19deg+-5deg b=53deg+-5deg
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=16deg
----------
a=(90deg)
----------
aa=16deg
----------
a=(90deg)
Information:
3. Remove bearing caps (1) from the two connecting rods. Put pieces of rubber hose or tape on the threads of the connecting rod bolts as protection for the crankshaft. 4. Push the pistons up until the piston rings are clear of the cylinder liner. Remove pistons (2). Keep each cap with its connecting rod.
Do not turn the crankshaft while any of the connecting rods are in the engine without the caps installed. Do not cause damage to the cooling tubes when the pistons are removed.
5. Do Steps 1 through 4 for the remainder of the pistons.Install Pistons
1. Put clean engine oil on the piston rings and cylinder liners. 2. Put two pistons in position opposite of each other in the correct bore of the block. Install pistons (1) with tool (A).
Make sure that the pistons are installed with flat surfaces (2) of the connecting rods toward each other and the chamfered sides (4) toward the crankshaft.
For more detail about the installation of connecting rod bearings see REMOVE AND INSTALL CONNECTING ROD BEARINGS.3. Check the bearing clearances with tool (B). 4. Put clean engine oil on bolts (5) and the connecting rod bearings. Install caps (3) and nuts finger tight. Tighten each nut to a torque of 60 6 lb.ft. (80 8 N m). Put a mark across the nuts and bolts. Tighten each nut 120° more.5. Check the side clearance between two connecting rods on the same crankshaft journal. Clearance must be .011 to .033 in. (0.28 to 0.84 mm) for new rods.6. Do Steps 1 through 5 for the remainder of the pistons.
Do not turn the crankshaft while any of the connecting rods are in the engine without the caps installed. Do not cause damage to the cooling tubes when the pistons are removed.
5. Do Steps 1 through 4 for the remainder of the pistons.Install Pistons
1. Put clean engine oil on the piston rings and cylinder liners. 2. Put two pistons in position opposite of each other in the correct bore of the block. Install pistons (1) with tool (A).
Make sure that the pistons are installed with flat surfaces (2) of the connecting rods toward each other and the chamfered sides (4) toward the crankshaft.
For more detail about the installation of connecting rod bearings see REMOVE AND INSTALL CONNECTING ROD BEARINGS.3. Check the bearing clearances with tool (B). 4. Put clean engine oil on bolts (5) and the connecting rod bearings. Install caps (3) and nuts finger tight. Tighten each nut to a torque of 60 6 lb.ft. (80 8 N m). Put a mark across the nuts and bolts. Tighten each nut 120° more.5. Check the side clearance between two connecting rods on the same crankshaft journal. Clearance must be .011 to .033 in. (0.28 to 0.84 mm) for new rods.6. Do Steps 1 through 5 for the remainder of the pistons.