Information injection-pump assembly
BOSCH
F 019 Z10 728
f019z10728
ZEXEL
101605-0081
1016050081
ISUZU
1156033862
1156033862
Rating:
Service parts 101605-0081 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 728
f019z10728
ZEXEL
101605-0081
1016050081
ISUZU
1156033862
1156033862
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
134424-4120
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
4.4
4.35
4.45
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
A
Rack position
7.6
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
71
69.4
72.6
Max. variation between cylinders
%
0
-2.5
2.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
6.5+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
13
11.7
14.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Main spring setting
(4)Set idle sub-spring
----------
K=7
----------
----------
K=7
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=13deg+-5deg b=32deg+-5deg
----------
----------
a=13deg+-5deg b=32deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
(2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
a=32deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=32deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=22deg
----------
a=(90deg)
----------
aa=22deg
----------
a=(90deg)
Information:
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove the carbon ring and lip from the inner surface of the cylinder liner. 2. Turn the crankshaft until two of the pistons are at bottom center. Remove the nuts and bolts (1) from the connecting rods that are at bottom center. Remove connecting rod caps (2), and put identification marks on them for installation purposes.
Do not let the connecting rods hit the crankshaft or the bottom edge of the cylinder liners when the pistons are removed.
3. Push the connecting rods and pistons away from the crankshaft until the piston rings are out of the cylinder liners. Remove the two pistons from the engine.4. Keep each connecting rod cap with its respective connecting rod and piston. Put identification marks on each piston as to its location in the engine.5. Do Steps 1 through 4 for the removal of the remaining pistons.Install Pistons And Connecting Rods
1. Turn the crankshaft until the bearing journals for the pistons to be installed are at bottom center.2. Put clean engine oil on the crankshaft journals and on the inside of the cylinder liners. Put clean engine oil on the piston rings and the connecting rod bearings.3. Move the piston rings on the pistons until the ring openings are approximately 90° apart. 4. Put the piston in the cylinder liner with the "V" mark on the piston in alignment with the "V" mark on the cylinder block. Put tooling (A) in position on the cylinder block and compress the piston rings.5. Push the piston into the cylinder liner and out of the ring compressor. 6. Pull the connecting rod into position on the crankshaft as shown. Install connecting rod bolts (1) in the connecting rods.7. Put clean engine oil on the lower half of the connecting rod bearing. Put 2P2506 Thread Lubricant on the bolt threads and on the surfaces of the nuts that make contact with the rod caps.
When the connecting rod caps are installed, make sure the number on the side of the cap is next to and respective with the number on the side of the connecting rod.
8. Install connecting rod caps (2) and the nuts that hold them. Tighten the nuts to a torque of 41 4 N m (30 3 lb ft). Put a mark on each nut as to its location, and tighten them 90° 5° more.9. Perform Steps 1 through 8 for the remainder of the pistons.End By:a. install oil pumpb. install oil pan platec. install spacer plate
Perform Scheduled Oil Sampling on oil wetted compartments after performing service work to check for contaminants left in the system following repair. Contaminants put into the system may cause rapid wear and shortened component life.
Disassemble Pistons And Connecting Rods
Start By:a. remove pistons and connecting rods
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove the rings from the