101603-8610 ZEXEL F 019 Z10 010 BOSCH INJECTION-PUMP ASSEMBLY f019z10010 1016038610

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 010 f019z10010

ZEXEL 101603-8610 1016038610

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Service parts 101603-8610 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6250

3. GOVERNOR 105932-1100

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105643-1050

6. COUPLING PLATE 105661-0840

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4282

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105030-4700

14. NOZZLE 105025-0530

15. NOZZLE SET

Include in #1:

101603-8610 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5481 as _

Cross reference number

BOSCH F 019 Z10 010 f019z10010

ZEXEL 101603-8610 1016038610

Zexel num

Bosch num

Firm num

Name

101603-8610
101603-8611

F 019 Z10 010

INJECTION-PUMP ASSEMBLY
* K

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.2 4.15 4.25

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 10.9

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 65.5 63.9 67.1

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.

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.9)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 65.5 64.5 66.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.45

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 85.5 81.5 89.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 52.5 49.3 55.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 100 100 108

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1000

Advance angle deg. 3 2.5 3.5

Remarks
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)RACK LIMIT
----------
T1=K77
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=12deg+-5deg b=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg

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=(160deg)

Information:

2. Remove four bolts (2), nuts and cover that connect air inlet pipe (1) to the aftercooler cover.3. Put a mark on the turbocharger compressor housing in alignment with a mark on the turbocharger cartridge housing. Loosen the bolts for the turbocharger compressor housing. Carefully turn housing so air inlet pipe (1) is away from the aftercooler cover. 4. Remove bolts (3) that hold the aftercooler cover to the aftercooler base. Remove aftercooler cover (4). 5. Remove pipe (7), coupling, four bolts (5), elbow (6) and adapter (8).6. Remove the two brackets that hold the water inlet pipe to the timing gear cover. 7. Remove four bolts (9) and move elbow (10) and adapter (11) away from the aftercooler base.8. Remove the aftercooler core from the aftercooler base.Install Aftercooler Core
1. Install new O-ring seals (1) in the aftercooler core.2. Put aftercooler core (2) in position in the aftercooler base with the end that has the identification "Fresh Water" to the water inlet end of the aftercooler base. 3. Install a new O-ring seal on elbow (3). Put adapter (5) and elbow (3) in position on the aftercooler base and install four bolts (4). 4. Install new O-ring seals on elbow (7) and coupling (8).5. Install adapter (9), elbow (7), four bolts (6), coupling and pipe (10).6. Put the aftercooler cover in position on the aftercooler base and install the bolts that hold the cover to the base.7. Carefully turn the turbocharger compressor housing so the mark on the housing is in alignment with the mark on the turbocharger cartridge housing. Tighten the bolts for the compressor housing to 105 5 lb.in. (11.9 0.6 N m).
Do not cause damage to the O-ring seal between the turbocharger compressor housing and the cartridge housing.
8. Install the cover, four bolts (12) and nuts that connect air inlet pipe (11) to the aftercooler cover.9. Fill the engine with coolant.