Information injection-pump assembly
BOSCH
F 019 Z10 601
f019z10601
ZEXEL
101603-7671
1016037671
ISUZU
1156026951
1156026951
Rating:
Service parts 101603-7671 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
1-15300-213-1
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Include in #1:
101603-7671
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-1872
as _
Cross reference number
BOSCH
F 019 Z10 601
f019z10601
ZEXEL
101603-7671
1016037671
ISUZU
1156026951
1156026951
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
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
10.9
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
H
Rack position
9.5+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
9.1
7.8
10.4
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(10.9)
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+0.1
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
84.4
80.4
88.4
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
98
98
130
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1275--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1225
Advance angle
deg.
0.5
Load
3/4
Timer adjustment_03
Pump speed
r/min
1275
Advance angle
deg.
0.5
Load
4/4
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
5.5
5
6
Load
4/4
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)Air cylinder operating pressure: P1 or more
(4)Air cylinder operating pressure: P2
----------
T1=F89 P1=294kPa(3kg/cm2) P2=0kPa(0kg/cm2)
----------
----------
T1=F89 P1=294kPa(3kg/cm2) P2=0kPa(0kg/cm2)
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
(3)Air cylinder operating pressure: at P1
(4)When air cylinder OFF.
----------
aa=35mm P1=294kPa(3kg/cm2)
----------
a=42deg+-5deg b=29deg+-3deg c=22.5deg+-3deg
----------
aa=35mm P1=294kPa(3kg/cm2)
----------
a=42deg+-5deg b=29deg+-3deg c=22.5deg+-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=131153-6420 ST=A743 L1=1mm L2=3.6+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-6420 ST=A743 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)-
----------
aa=8deg
----------
a=(60deg)
----------
aa=8deg
----------
a=(60deg)
Information:
Problem
The fuel lines on certain 3408 Generator Set, Industrial, and Marine engines may fail. New fuel line groups can be installed that have a longer service life.
Affected Product
Model & Identification Number
3408 (67U12405-15199; 78Z2829-4522; 99U5985-7229)
Parts Needed
1 - 6I0030 Fuel Line Group6 - 5M2894 Washer6 - 0S0509 BoltAdditional Parts Needed For DIT Engines (Non-Aftercooled)
5 - 5M2894 Washer1 - 4P8261 Bracket1 - 4P8385 Bracket2 - 5P0537 Washer5 - 0S1571 Bolt2 - 0S1615 Bolt3 - 8T1296 WasherAction Required
Parts Stock
Make sure that all 7C6931, 7C6932, 7C6933, 7C6934, 7C6935, 7C6936, 7C6937 and 7C6938 Fuel Lines were removed from parts stock while implementing Product Support Program PS4737.
Affected Product
Remove the existing fuel lines and install the new fuel injection line groups as a group. See the attached rework procedure.
Do not over tighten the screws of the metal-to- metal fuel line clamps. Use a 6V6069 Torgue Screwdriver or similar tool to tighten the screw to a torgue of 2.25 N m (20 lb in).
Service Claim Allowances
Parts Stock
Refer to the Product Support Program PS4737.
Affected Product
This is a 2.2-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Refer to the parts list and illustrations. Replace the existing fuel lines and their related parts with the new 6I0030 Fuel Line Group.
To insure that the clamp locations are correct, install fuel line group as assembled. In a case where it is necessary to remove the clamps, mark their locations to insure the correct position when assembling.
1. Clean and paint the new 6I0030 Fuel Line Group before proceeding to the job site.A) Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the lines.B) Clean and paint the fuel line group.C) After drying, do not remove the plastic plugs and caps until the fuel line group is ready to be installed on the engine. Transport the fuel line group in it's original shipping box. If the engine to be reworked is non-aftercooled, also clean and pre-paint the new 4P8385 and 4P8261 Brackets.
2. Remove all the mounting bolts from the fuel line bracket at the aftercooler housing on DITA engines or at the 6N1671 Bracket on DIT engines. The 6N1671 Bracket in the vee of the DIT (non- aftercooled) engines is used to support the fuel line brackets. This bracket is part of the 6N1672 Fastener Group, Affected Product not having an aftercooler required a new two piece bracket.
3. Disconnect all the fuel line nuts at the fuel injection pump and at the adapters in the valve cover bases.4. a) Remove the old fuel line group.b) On DIT engines only, remove the 6N1671 Bracket from the vee of the engine and install the new brackets. Illustrations 2 and 3 show how the new brackets are installed. The 4P8385 Bracket and 4P8261 Bracket are the 2 main parts of this group. Five 0S1571 Bolts and five 5M2894 Washers attach the assembly to the block. To align the assembly correctly, three 8T1296 Washers are reguired to shim the brackets to the block (see Illustration
The fuel lines on certain 3408 Generator Set, Industrial, and Marine engines may fail. New fuel line groups can be installed that have a longer service life.
Affected Product
Model & Identification Number
3408 (67U12405-15199; 78Z2829-4522; 99U5985-7229)
Parts Needed
1 - 6I0030 Fuel Line Group6 - 5M2894 Washer6 - 0S0509 BoltAdditional Parts Needed For DIT Engines (Non-Aftercooled)
5 - 5M2894 Washer1 - 4P8261 Bracket1 - 4P8385 Bracket2 - 5P0537 Washer5 - 0S1571 Bolt2 - 0S1615 Bolt3 - 8T1296 WasherAction Required
Parts Stock
Make sure that all 7C6931, 7C6932, 7C6933, 7C6934, 7C6935, 7C6936, 7C6937 and 7C6938 Fuel Lines were removed from parts stock while implementing Product Support Program PS4737.
Affected Product
Remove the existing fuel lines and install the new fuel injection line groups as a group. See the attached rework procedure.
Do not over tighten the screws of the metal-to- metal fuel line clamps. Use a 6V6069 Torgue Screwdriver or similar tool to tighten the screw to a torgue of 2.25 N m (20 lb in).
Service Claim Allowances
Parts Stock
Refer to the Product Support Program PS4737.
Affected Product
This is a 2.2-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Refer to the parts list and illustrations. Replace the existing fuel lines and their related parts with the new 6I0030 Fuel Line Group.
To insure that the clamp locations are correct, install fuel line group as assembled. In a case where it is necessary to remove the clamps, mark their locations to insure the correct position when assembling.
1. Clean and paint the new 6I0030 Fuel Line Group before proceeding to the job site.A) Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the lines.B) Clean and paint the fuel line group.C) After drying, do not remove the plastic plugs and caps until the fuel line group is ready to be installed on the engine. Transport the fuel line group in it's original shipping box. If the engine to be reworked is non-aftercooled, also clean and pre-paint the new 4P8385 and 4P8261 Brackets.
2. Remove all the mounting bolts from the fuel line bracket at the aftercooler housing on DITA engines or at the 6N1671 Bracket on DIT engines. The 6N1671 Bracket in the vee of the DIT (non- aftercooled) engines is used to support the fuel line brackets. This bracket is part of the 6N1672 Fastener Group, Affected Product not having an aftercooler required a new two piece bracket.
3. Disconnect all the fuel line nuts at the fuel injection pump and at the adapters in the valve cover bases.4. a) Remove the old fuel line group.b) On DIT engines only, remove the 6N1671 Bracket from the vee of the engine and install the new brackets. Illustrations 2 and 3 show how the new brackets are installed. The 4P8385 Bracket and 4P8261 Bracket are the 2 main parts of this group. Five 0S1571 Bolts and five 5M2894 Washers attach the assembly to the block. To align the assembly correctly, three 8T1296 Washers are reguired to shim the brackets to the block (see Illustration