Information injection-pump assembly
BOSCH
F 019 Z10 731
f019z10731
ZEXEL
101605-0210
1016050210
ISUZU
1156034580
1156034580
Rating:
Service parts 101605-0210 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
Include in #1:
101605-0210
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-1041
as _
Cross reference number
BOSCH
F 019 Z10 731
f019z10731
ZEXEL
101605-0210
1016050210
ISUZU
1156034580
1156034580
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
255
255
Overflow valve opening pressure
kgf/cm2
2.6
2.6
2.6
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
4.2
4.15
4.25
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
10.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
101
99.5
102.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
113
113
Boost pressure
mmHg
850
850
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.7+-0.5
Pump speed
r/min
450
450
450
Average injection quantity
mm3/st.
12
10.7
13.3
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
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
E
Rack position
10.8++
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
R1-1.65
Boost pressure
kPa
17.3
13.3
21.3
Boost pressure
mmHg
130
100
160
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
R1(10.6)
Boost pressure
kPa
100
93.3
106.7
Boost pressure
mmHg
750
700
800
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)Main spring setting
(6)Boost compensator stroke: BCL
----------
K=14 BCL=1.65+-0.1mm
----------
----------
K=14 BCL=1.65+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=11deg+-5deg b=21deg+-5deg
----------
----------
a=11deg+-5deg b=21deg+-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, assemble then tighten the bolts to remove the heads.
(B): Specified torque
(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=7.5deg
----------
a=(110deg)
----------
aa=7.5deg
----------
a=(110deg)
Information:
Intake and exhaust valve stems are to be coated with 8T2998 Break-in Lubricant prior to installation in the cylinder head.(1) Exhaust valve.(2) Intake valve.(3) 7C4273 Spring for valves. Free length ... 71.0 mm (2.80 in)Assembled length ... 65.86 mm (2.593 in)Load at assembled length ... 217 22 N (49 5 lb)Minimum operating length ... 50.7 mm (2.00 in)Load at minimum operating length ... 858 40 N (193 9 lb)(4) Height to top of valve guides ... 23.0 0.5 mm (.906 .020 in) Install valve guide with 12.065 mm diameter on spring side of the head.Assemble with seal seated against top of valve guide.(5) Diameter of valve stems (new) ... 8.000 0.008 mm (.3150 .0003 in) "Use again" minimum diameter of valve stems ... 7.965 mm (.3136 in)Bore in valve guides with guides installed in head ... 8.045 0.010 mm (.3167 .0004 in)"Use again" maximum bore in valve guides with guides installed in head ... 8.080 mm (.3181 in)(6) Diameter of valve head: Intake valve ... 47.00 0.13 mm (1.850 .005 in)Exhaust valve ... 40.00 0.13 mm (1.575 .005 in)(7) Angle of valve faces: Intake valve ... 29 1/4 1/4°Exhaust valve ... 45 1/4° (8) Diameter of valve seat inserts: Intake valve ... 50.000 0.013 mm (1.9685 .0005 in)Exhaust valve ... 43.000 0.013 mm (1.6929 .0005 in)Bore in head for valve seat insert:Intake valve ... 49.931 0.013 mm (1.9658 .0005 in)Exhaust valve ... 42.931 0.013 mm (1.6902 .0005 in)Valve seat insert must be shrunk by reduced temperature before installing in head.(9) Angle of valve seat inserts: Intake valve ... 30 1°Exhaust valve ... 45 1°(10) Depth of bore in head for valve seat insert ... 10.00 0.13 mm (.394 .005 in)(11) Outside diameter of the seating face of the valve seat insert: Intake valve ... 45.880 0.085 mm (1.8063 .0033 in)Exhaust valve ... 39.135 0.046 mm (1.5407 .0018 in)(12) "Use again" thickness of valve lip: Intake valve ... 1.80 mm (.071 in)Exhaust valve ... 1.50 mm (.059 in)