Information injection-pump assembly
BOSCH
F 019 Z10 113
f019z10113
ZEXEL
101603-4310
1016034310
ISUZU
1156019052
1156019052
Rating:
Service parts 101603-4310 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-104-2
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 113
f019z10113
ZEXEL
101603-4310
1016034310
ISUZU
1156019052
1156019052
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
132424-0620
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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
1-5-3-6-
2-4
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 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.4
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
70.7
69.1
72.3
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
9.6+-0.5
Pump speed
r/min
260
260
260
Average injection quantity
mm3/st.
9.4
8.1
10.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.4)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
70.7
69.7
71.7
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
(R1-0.4)
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
76
74.4
77.6
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
86
86
96
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
550--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
500
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=A66
----------
----------
T1=A66
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=42deg+-5deg b=35deg+-3deg
----------
aa=35mm
----------
a=42deg+-5deg b=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
0000001501 TAMPER PROOF
Tamper proof adjustment
(1)Set the full load screw at rack position Ra+0.4.
(2)Set the full load position Ra using screw (A).
----------
Ra=R1(11.4)mm
----------
----------
Ra=R1(11.4)mm
----------
Timing setting
(1)Pump vertical direction
(2)Position of timer's threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=14deg
----------
a=(60deg)
----------
aa=14deg
----------
a=(60deg)
Information:
start by: a) remove fuel injection pumpsb) separation of governor from fuel injection pump housingc) remove fuel transfer pump1. Loosen the screws that hold the levers to the shaft assembly. 2. Remove the screw (1) that holds the lever assembly (2) to the shaft assembly. 3. Remove the shaft assembly (5) from the housing and remove the levers (3) and lever assembly (2).4. Loosen the screws that hold the levers (6) to the shaft.5. Remove the screw that holds the lever (4) to the shaft.6. Remove the shaft (7) from the housing and remove the levers. 7. Remove the lifter and roller assemblies (8) from the housing with a magnet. Put identification on the lifters (10) and rollers (9) for installation in their respective bores in the housing. 8. Remove the camshaft (11) from the housing.
Do not use a force to remove the camshaft. Turn the camshaft to permit the free passage of the camshaft by the bosses (12) in the housing.
Assemble Fuel Injection Pump Housing
1. Install the camshaft (1) in the housing.
Do not use a force to install the camshaft. Turn the camshaft to permit the free passage of the camshaft by the bosses in the housing.
2. Install the lifter and roller assemblies (2) in their respective bores in the housing with a magnet. Install the lifters with their grooves in alignment with the pins (3) in the housing. 3. Put the shaft (4) in the housing. Slide the levers (6) and the lever (5) on to the shaft in the order shown. Push the shaft into position in the housing. 4. Install the screw that holds the lever (5) to the shaft. Tighten the screw to a torque of 24 2 lb.in. (27.7 2.3 cm.kg). 5. Put the shaft assembly (7) in the housing. Slide the levers (9) and the lever assembly (8) on to the shaft in the order shown. Push the shaft assembly into position in the housing. 6. Install the screw that holds the lever assembly (8) to the shaft assembly. Tighten the screw to a torque of 24 2 lb. in. (27.7 2.3 cm.kg).end by: a) make adjustments to the sleeve control shafts (see TESTING AND ADJUSTING)b) install fuel transfer pumpc) connection of governor to fuel injection pump housingd) install fuel injection pumps
Do not use a force to remove the camshaft. Turn the camshaft to permit the free passage of the camshaft by the bosses (12) in the housing.
Assemble Fuel Injection Pump Housing
1. Install the camshaft (1) in the housing.
Do not use a force to install the camshaft. Turn the camshaft to permit the free passage of the camshaft by the bosses in the housing.
2. Install the lifter and roller assemblies (2) in their respective bores in the housing with a magnet. Install the lifters with their grooves in alignment with the pins (3) in the housing. 3. Put the shaft (4) in the housing. Slide the levers (6) and the lever (5) on to the shaft in the order shown. Push the shaft into position in the housing. 4. Install the screw that holds the lever (5) to the shaft. Tighten the screw to a torque of 24 2 lb.in. (27.7 2.3 cm.kg). 5. Put the shaft assembly (7) in the housing. Slide the levers (9) and the lever assembly (8) on to the shaft in the order shown. Push the shaft assembly into position in the housing. 6. Install the screw that holds the lever assembly (8) to the shaft assembly. Tighten the screw to a torque of 24 2 lb. in. (27.7 2.3 cm.kg).end by: a) make adjustments to the sleeve control shafts (see TESTING AND ADJUSTING)b) install fuel transfer pumpc) connection of governor to fuel injection pump housingd) install fuel injection pumps