Information injection-pump assembly
BOSCH
F 019 Z10 114
f019z10114
ZEXEL
101603-8470
1016038470
ISUZU
8943957490
8943957490
Rating:
Service parts 101603-8470 INJECTION-PUMP ASSEMBLY:
1.
_
3.
GOVERNOR
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
16.2{165}/18.1{185}
15.
NOZZLE SET
Include in #1:
101603-8470
as INJECTION-PUMP ASSEMBLY
Include in #2:
104741-5352
as _
Cross reference number
BOSCH
F 019 Z10 114
f019z10114
ZEXEL
101603-8470
1016038470
ISUZU
8943957490
8943957490
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
4.7
4.65
4.75
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
Beginning of injection position
Governor side NO.1
Governor 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
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
86.5
84.9
88.1
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
275
275
275
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(13)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
86.5
85.5
87.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.15
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
95.5
92.3
98.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.25
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
77.5
74.3
80.7
Fixing the lever
*
Timer adjustment
Pump speed
r/min
905--
Advance angle
deg.
0
0
0
Load
3/5
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
855
Advance angle
deg.
0.3
Load
3/5
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
1.5
1
2
Load
5/5
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1110
Advance angle
deg.
1.5
1
2
Load
3/5
Timer adjustment_05
Pump speed
r/min
1450
Advance angle
deg.
7
6.5
7.5
Load
5/5
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.
----------
T1=K09
----------
----------
T1=K09
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=60mm
----------
a=28.5deg+-5deg b=40deg+-3deg
----------
aa=60mm
----------
a=28.5deg+-5deg b=40deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-5deg b=40deg+-5deg
----------
aa=46.5mm
----------
a=34.5deg+-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=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------
----------
PL=131153-9020 ST=A769 L1=1mm L2=4.7+-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)At rack position = bb
----------
aa=6deg bb=R1(13)mm
----------
a=(150deg)
----------
aa=6deg bb=R1(13)mm
----------
a=(150deg)
Information:
2. Remove nuts (1) from studs for main bearing caps (2).3. Remove the main bearing caps.4. Install rubber hose over each of the two studs at both ends of the block. This will protect the crankshaft during removal and installation. 5. Remove the crankshaft from the cylinder block. Weight of crankshaft is 300 lb. (136 kg).6. Remove the main bearings from cylinder block and main bearing caps.
If main bearings are not replaced, old bearings must be installed in same location from which they were removed.
Install Crankshaft
1. Put timing marks (1) on all timing gears in alignment.2. Clean surfaces for bearings in cylinder block. Install upper halves of bearings in block. Put clean oil on bearings.
If replacement of the bearings is not made, old bearings must be installed in same location from which they were removed.
3. Clean bearing caps, and install lower halves of bearings in caps. 4. Fasten a hoist to crankshaft and put it into place in the block with "V" mark on crankshaft gear in alignment with "V" mark on cluster gear. 5. Check bearing clearance with wire (A). Install bearing caps, and tighten both nuts to 75 5 lb. ft. (101.7 6.8 N m). Put a mark across the nuts and studs, and turn nuts an additional 120° from mark. Remove caps and check thickness of wire (A) to find bearing clearance. Bearing clearance must be .0035 to .0066 in. (0.089 to 0.168 mm) for new parts. Maximum permissible clearance for used parts is .010 in. (0.25 mm).6. Put clean oil on threads of studs, face of nuts, and lower halves of bearings. Put bearing caps in their respective positions with number on cap same as number on block, and groove in bearing cap on same side as groove in cylinder block. Install nuts and tighten to 75 5 lb.ft. (101.7 6.8 N m). Put a mark across the nuts and studs, and turn nuts an additional 120° from mark. 7. Use indicator group (B) to check the crankshaft end plate as controlled by lower bearing of No. 7 bearing cap. End play with new parts should be .006 to .018 in. (0.15 to 0.46 mm). Maximum permissible end play with used parts is .035 in. (0.89 mm).end by: a) install flywheel housingb) install front coverc) install pistonsd) install engine and torque divider
If main bearings are not replaced, old bearings must be installed in same location from which they were removed.
Install Crankshaft
1. Put timing marks (1) on all timing gears in alignment.2. Clean surfaces for bearings in cylinder block. Install upper halves of bearings in block. Put clean oil on bearings.
If replacement of the bearings is not made, old bearings must be installed in same location from which they were removed.
3. Clean bearing caps, and install lower halves of bearings in caps. 4. Fasten a hoist to crankshaft and put it into place in the block with "V" mark on crankshaft gear in alignment with "V" mark on cluster gear. 5. Check bearing clearance with wire (A). Install bearing caps, and tighten both nuts to 75 5 lb. ft. (101.7 6.8 N m). Put a mark across the nuts and studs, and turn nuts an additional 120° from mark. Remove caps and check thickness of wire (A) to find bearing clearance. Bearing clearance must be .0035 to .0066 in. (0.089 to 0.168 mm) for new parts. Maximum permissible clearance for used parts is .010 in. (0.25 mm).6. Put clean oil on threads of studs, face of nuts, and lower halves of bearings. Put bearing caps in their respective positions with number on cap same as number on block, and groove in bearing cap on same side as groove in cylinder block. Install nuts and tighten to 75 5 lb.ft. (101.7 6.8 N m). Put a mark across the nuts and studs, and turn nuts an additional 120° from mark. 7. Use indicator group (B) to check the crankshaft end plate as controlled by lower bearing of No. 7 bearing cap. End play with new parts should be .006 to .018 in. (0.15 to 0.46 mm). Maximum permissible end play with used parts is .035 in. (0.89 mm).end by: a) install flywheel housingb) install front coverc) install pistonsd) install engine and torque divider