Information injection-pump assembly
BOSCH
F 019 Z10 477
f019z10477
ZEXEL
101402-4250
1014024250
Rating:
Service parts 101402-4250 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-103-2
12.
Open Pre:MPa(Kqf/cm2)
14.7(150)
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 477
f019z10477
ZEXEL
101402-4250
1014024250
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
7.9
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
63.2
62.1
64.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.9+-0.5
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
8
6.6
9.4
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
86
86
96
Fixing the lever
*
Rack limit
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)RACK LIMIT
(3)Set idle sub-spring
(4)Main spring setting
(5)Rack difference between N = N1 and N = N2
----------
K=17 N1=1200r/min N2=700r/min
----------
----------
K=17 N1=1200r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
----------
----------
a=(9deg)+-5deg b=(22deg)+-5deg c=32deg+-3deg
----------
----------
a=(9deg)+-5deg b=(22deg)+-5deg c=32deg+-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=18deg
----------
a=(90deg)
----------
aa=18deg
----------
a=(90deg)
Information:
start by:a) remove oil pumpb) remove timing gear coverc) remove flywheel housingd) remove pistons For more detail about removal of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS. 1. Check each bearing cap (1) for its location on the engine. Each cap has an arrow which is toward the front of the block and a number which gives the location of that cap. Keep each bearing with the correct cap. 2. Remove bearing caps No. 2 through No. 4. Remove thrust plates from No. 3 upper bearing.3. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft as shown. Remove No. 1 and No. 5 main bearing caps. Remove the crankshaft. Weight of the crankshaft is 270 lb. (122 kg).
Be careful not to cause damage to the crankshaft journals when the crankshaft is removed.
4. Remove crankshaft gear (2) with tooling (A).5. Remove dowel and pin from crankshaft with tooling (B).Install Crankshaft
1. Install pin (1) in the crankshaft end until it is extended from the surface .25 .02 in. (6.4 0.5 mm).2. Install dowel (2) until it is extended from the surface .16 .02 in. (4.1 0.5 mm). 3. Heat crankshaft gear (3) to a maximum temperature of 400°F (204°C). Install gear (3) on the crankshaft with groove (4) in alignment with dowel (2).4. Make sure the upper main bearings are clean. Put clean oil on the upper main bearings and journals of the crankshaft.5. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and put it in position in the block.
Do not cause damage to the crankshaft journals. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear.
For more detail about installation of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS.6. Check the bearing clearances with tool (B).7. Put clean engine oil on the bolts for caps No. 1 and No. 5. Install No. 1 and No. 5 caps with the bolts finger tight. Make sure the arrows on the caps are toward the front of the block. 8. Install thrust plates (5) for the No. 3 upper main bearing. Install the thrust plates with the side that has the identification "Block Side" toward the cylinder block.9. Put clean oil on the bolts for caps No. 2 through No. 4. Install caps No. 2 through No. 4 with the bolts finger tight. Make sure the arrows are toward the front of the block.10. Tighten the cap bolts as follows: a) Tighten the bolts on the tab end of the caps first to a torque of 190 10 lb. ft. (260 14 N m).b) Tighten the bolts on the other end of the caps to a torque of 190 10 lb. ft. (260 14 N m).c) Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end
Be careful not to cause damage to the crankshaft journals when the crankshaft is removed.
4. Remove crankshaft gear (2) with tooling (A).5. Remove dowel and pin from crankshaft with tooling (B).Install Crankshaft
1. Install pin (1) in the crankshaft end until it is extended from the surface .25 .02 in. (6.4 0.5 mm).2. Install dowel (2) until it is extended from the surface .16 .02 in. (4.1 0.5 mm). 3. Heat crankshaft gear (3) to a maximum temperature of 400°F (204°C). Install gear (3) on the crankshaft with groove (4) in alignment with dowel (2).4. Make sure the upper main bearings are clean. Put clean oil on the upper main bearings and journals of the crankshaft.5. Install one of the flywheel bolts in each end of the crankshaft. Fasten a hoist to the crankshaft and put it in position in the block.
Do not cause damage to the crankshaft journals. Make sure the "V" mark on the crankshaft gear is in alignment with the "V" mark on the idler gear.
For more detail about installation of main bearings see REMOVE AND INSTALL CRANKSHAFT MAIN BEARINGS.6. Check the bearing clearances with tool (B).7. Put clean engine oil on the bolts for caps No. 1 and No. 5. Install No. 1 and No. 5 caps with the bolts finger tight. Make sure the arrows on the caps are toward the front of the block. 8. Install thrust plates (5) for the No. 3 upper main bearing. Install the thrust plates with the side that has the identification "Block Side" toward the cylinder block.9. Put clean oil on the bolts for caps No. 2 through No. 4. Install caps No. 2 through No. 4 with the bolts finger tight. Make sure the arrows are toward the front of the block.10. Tighten the cap bolts as follows: a) Tighten the bolts on the tab end of the caps first to a torque of 190 10 lb. ft. (260 14 N m).b) Tighten the bolts on the other end of the caps to a torque of 190 10 lb. ft. (260 14 N m).c) Put a mark across the bolt head and cap. Tighten the bolts opposite the tab end