Information injection-pump assembly
BOSCH
F 019 Z10 829
f019z10829
ZEXEL
101603-7443
1016037443
Rating:
Service parts 101603-7443 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-266-4
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Include in #1:
101603-7443
as INJECTION-PUMP ASSEMBLY
Include in #2:
104742-1341
as _
Cross reference number
BOSCH
F 019 Z10 829
f019z10829
ZEXEL
101603-7443
1016037443
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
1-5-3-6-
2-4
Pre-stroke
mm
3.6
3.55
3.65
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
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
13.3
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
98.6
97
100.2
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
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
8
6.7
9.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(13.3)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
98.6
97.6
99.6
Basic
*
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.15
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
98.6
95.4
101.8
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_05
Adjusting point
C
Rack position
R2(R1-0.
55)
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
78.6
75.4
81.8
Fixing the lever
*
Boost pressure
kPa
33.3
33.3
Boost pressure
mmHg
250
250
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2-1.35
Pump speed
r/min
550
550
550
Average injection quantity
mm3/st.
54
50.8
57.2
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
93
61
125
Fixing the lever
*
Boost compensator adjustment
Pump speed
r/min
550
550
550
Rack position
R2-1.35
Boost pressure
kPa
3.3
3.3
5.7
Boost pressure
mmHg
25
25
45
Boost compensator adjustment_02
Pump speed
r/min
550
550
550
Rack position
R2(R1-0.
55)
Boost pressure
kPa
20
20
20
Boost pressure
mmHg
150
150
150
Timer adjustment
Pump speed
r/min
(1170)
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1325
Advance angle
deg.
1.5
1
2
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Boost compensator stroke: BCL
----------
T1=F36 BCL=1.35+-0.1mm
----------
----------
T1=F36 BCL=1.35+-0.1mm
----------
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=43deg+-5deg b=(37deg)+-3deg
----------
aa=35mm
----------
a=43deg+-5deg b=(37deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=25deg+-5deg b=40deg+-5deg
----------
----------
a=25deg+-5deg b=40deg+-5deg
0000001501 I/P WITH LOAD PLUNGER ADJ
Plunger assembly number: PL (stamping: ST)
1. Adjustment procedures
(1)Insert the pre-stroke adjusting shims L1 for each cylinder.
(2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2)
(3)At basic point A, adjust so that the pre-stroke is L2.
(4)Reconfirm the injection quantity.
----------
PL=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-3720 ST=A716 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------
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)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
start by: a) remove pistons1. Check to be sure all coolant has been removed from the cylinder block.2. Put protection over the crankshaft bearing journals before removing cylinder liners.3. Put location marks on the cylinder liners with respect to their location in block. 4. Use tool setup (A) to remove the cylinder liners from block.5. Remove the seals from cylinder liners.6. Use a straight blade scraper to loosen the spacer plate (1) from cylinder block.
Use care when loosening the plate from cylinder block or damage to plate may result.
7. Remove the spacer plate (1).Install Cylinder Liners
1. Thoroughly clean both sides of spacer plate and top surface of block. Install spacer plate gasket and spacer plate on the cylinder block.
Make sure both sides of plate and top of block are clean and dry before installing gasket and plate. Do not put gasket adhesives or any other substance on these surfaces.
2. Put the cylinder liners in their respective positions in cylinder block. Install tool setup (B) and two cylinder head bolts and washers. Tighten the bolts to 70 5 lb.ft. (9.7 0.7 mkg).3. Check the cylinder liner projection using tool setup (C) as follows: a) Install the four spacers from tool group and four cylinder head bolts and washers. Tighten bolts to 70 5 lb.ft. (9.7 0.7 mkg).b) Use dial indicator, block, and gauge from the tool group to check liner projection at four locations around the liner.c) Cylinder liner projection must be .0030 to .0076 in. (0.076 to 0.193 mm). Projection between liners next to each other must not be different by more than .001 in. (0.025 mm). 4. Remove tool setup (B) and (C). Remove the liners from cylinder block.5. Install the O-ring seals on bottom of liners. Put liquid soap on the seals.
TYPICAL EXAMPLE6. Put oil on the filler band seal, and install the seal on top end of liner. Install the cylinder liners immediately into their respective locations in cylinder block using tool (A).
Do not let the filler band seal stay in oil except for a very short time because the oil will make the seal much bigger very fast. After putting oil on the filler band seal, install the liner immediately into block.
end by: a) install pistons.
Use care when loosening the plate from cylinder block or damage to plate may result.
7. Remove the spacer plate (1).Install Cylinder Liners
1. Thoroughly clean both sides of spacer plate and top surface of block. Install spacer plate gasket and spacer plate on the cylinder block.
Make sure both sides of plate and top of block are clean and dry before installing gasket and plate. Do not put gasket adhesives or any other substance on these surfaces.
2. Put the cylinder liners in their respective positions in cylinder block. Install tool setup (B) and two cylinder head bolts and washers. Tighten the bolts to 70 5 lb.ft. (9.7 0.7 mkg).3. Check the cylinder liner projection using tool setup (C) as follows: a) Install the four spacers from tool group and four cylinder head bolts and washers. Tighten bolts to 70 5 lb.ft. (9.7 0.7 mkg).b) Use dial indicator, block, and gauge from the tool group to check liner projection at four locations around the liner.c) Cylinder liner projection must be .0030 to .0076 in. (0.076 to 0.193 mm). Projection between liners next to each other must not be different by more than .001 in. (0.025 mm). 4. Remove tool setup (B) and (C). Remove the liners from cylinder block.5. Install the O-ring seals on bottom of liners. Put liquid soap on the seals.
TYPICAL EXAMPLE6. Put oil on the filler band seal, and install the seal on top end of liner. Install the cylinder liners immediately into their respective locations in cylinder block using tool (A).
Do not let the filler band seal stay in oil except for a very short time because the oil will make the seal much bigger very fast. After putting oil on the filler band seal, install the liner immediately into block.
end by: a) install pistons.