Information injection-pump assembly
BOSCH
F 019 Z10 730
f019z10730
ZEXEL
101605-0150
1016050150
ISUZU
1156034220
1156034220
Rating:
Service parts 101605-0150 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 730
f019z10730
ZEXEL
101605-0150
1016050150
ISUZU
1156034220
1156034220
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
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
9
Pump speed
r/min
1250
1250
1250
Average injection quantity
mm3/st.
102.5
101
104
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
61.3
61.3
Boost pressure
mmHg
460
460
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.9+-0.5
Pump speed
r/min
425
425
425
Average injection quantity
mm3/st.
10
8.7
11.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
E
Rack position
9.2++
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
105
100
110
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
R1-0.35
Boost pressure
kPa
34.7
30.7
38.7
Boost pressure
mmHg
260
230
290
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(9)
Boost pressure
kPa
48
41.3
54.7
Boost pressure
mmHg
360
310
410
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)RACK LIMIT
(4)Set idle sub-spring
(5)Boost compensator stroke: BCL
(6)Main spring setting
----------
K=8 BCL=0.35+-0.1mm
----------
----------
K=8 BCL=0.35+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=8deg+-5deg b=26deg+-5deg
----------
----------
a=8deg+-5deg b=26deg+-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)
0000001501 TAMPER PROOF
Tamperproofing-equipped boost compensator cover installation procedure
(A) After adjusting the boost compensator, tighten the bolts to remove the heads.
(1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
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=12deg
----------
a=(100deg)
----------
aa=12deg
----------
a=(100deg)
Information:
Start By:a. remove flywheel
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
When a replacement of the rear seal is made, a replacement of the wear sleeve is to be made also. 1. Remove the crankshaft rear seal with tool (A). 2. Install tool (C) as shown.3. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve in loose.4. Remove tool (C) and the wear sleeve by hand. The following steps are for the installation of the crankshaft rear seal and wear sleeve. 5. Install the crankshaft rear seal and wear sleeve with tooling (A) as follows:a. Put locator (1) in position on the crankshaft and install the three bolts that hold it in place.b. Put clean engine oil on the seal lip of seal (6) and on the outside diameter of wear sleeve (2).c. Install seal (6) on wear sleeve (2) from the end of the wear sleeve that has the bevel on the outside diameter. Make sure the lip of the seal is toward the inside of the engine and the bevel that is on the outside diameter of the wear sleeve is toward the outside of the engine when installed.d. Use 6V1541 Quick Cure Primer to clean the outside diameter of the crankshaft flange (3) and the inside diameter of wear sleeve (2).e. Put 9S3265 Retaining Compound on the outside diameter of crankshaft flange (3) and the inside diameter of wear sleeve (2). Make sure the lip of the seal is toward the inside of the engine and the outside diameter bevel of the wear sleeve is toward the outside of the engine.f. Put wear sleeve (2) with seal (6) on locator (1). Put installer (4) on locator (1) and install nut (5). Put lubrication on the face of the washer and the nut.g. Tighten nut (5) until installer (4) comes in contact with locator (1).h. Remove tooling (A) and check the wear sleeve and seal for correct installation.End By:a. install flywheel
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.
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
When a replacement of the rear seal is made, a replacement of the wear sleeve is to be made also. 1. Remove the crankshaft rear seal with tool (A). 2. Install tool (C) as shown.3. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve in loose.4. Remove tool (C) and the wear sleeve by hand. The following steps are for the installation of the crankshaft rear seal and wear sleeve. 5. Install the crankshaft rear seal and wear sleeve with tooling (A) as follows:a. Put locator (1) in position on the crankshaft and install the three bolts that hold it in place.b. Put clean engine oil on the seal lip of seal (6) and on the outside diameter of wear sleeve (2).c. Install seal (6) on wear sleeve (2) from the end of the wear sleeve that has the bevel on the outside diameter. Make sure the lip of the seal is toward the inside of the engine and the bevel that is on the outside diameter of the wear sleeve is toward the outside of the engine when installed.d. Use 6V1541 Quick Cure Primer to clean the outside diameter of the crankshaft flange (3) and the inside diameter of wear sleeve (2).e. Put 9S3265 Retaining Compound on the outside diameter of crankshaft flange (3) and the inside diameter of wear sleeve (2). Make sure the lip of the seal is toward the inside of the engine and the outside diameter bevel of the wear sleeve is toward the outside of the engine.f. Put wear sleeve (2) with seal (6) on locator (1). Put installer (4) on locator (1) and install nut (5). Put lubrication on the face of the washer and the nut.g. Tighten nut (5) until installer (4) comes in contact with locator (1).h. Remove tooling (A) and check the wear sleeve and seal for correct installation.End By:a. install flywheel
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.