101607-6161 ZEXEL F 019 Z10 377 BOSCH INJECTION-PUMP ASSEMBLY f019z10377 1016076161

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 377 f019z10377

ZEXEL 101607-6161 1016076161

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Service parts 101607-6161 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8391

3. GOVERNOR 105931-9431

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105672-5140

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7062

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 15.7(160)/21.6(220)

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE

15. NOZZLE SET 105019-0230

Include in #1:

101401-7740 as _

101607-6161 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 377 f019z10377

ZEXEL 101607-6161 1016076161

Zexel num

Bosch num

Firm num

Name

101607-6161
101607-6162

F 019 Z10 377

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 131424-8420

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 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 3.2 3.15 3.25

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 11.7

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 77.4 75.1 79.7

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 10.8 9.2 12.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.7)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77.4 76.4 78.4

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.55

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 87.7 83.7 91.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 56 52 60

Fixing the lever *

Injection quantity adjustment_06

Adjusting point E

Rack position (R1+0.5)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 87.6 83.6 91.6

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 91 81 101

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1080

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 2.5 2.5 2.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min 1390

Advance angle deg. 6 5.5 6.5

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=H50
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=18.5deg+-5deg b=(42deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee. (4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg

0000001501 MICRO SWITCH

Adjust the bolt to obtain the following lever position when the micro-switch is OFF. 1. Microswitch adjustment (OPEN type) Confirm with the lever angle at full. (1)Speed N1 (2)Rack position Ra
----------
N1=1675r/min Ra=8.5+-0.1mm
----------

0000001601 RACK SENSOR

V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------

0000001701 LEVER

(A) Idle (B) Full speed (C) Base lever (D) Accelerator lever (E) Accelerator lever delivery position 1. Measure speed lever angle (1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------

----------
b=(42deg)+-3deg c=18.5deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=10deg
----------
a=(2deg)

Information:

Table 9
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $01 CCM is the sending module
3 $25 IID 25
4 $07 Number of bytes
5 $58 GSC number 1
6, 7 $00 $82 PID $0082 GSC Fault Log Codes, Status, And Number of occurrences
8, 9 $00 $BE CID 190 (engine speed sensor fault)
10 $C3 Count included, inactive fault, logged fault, standard FMI (3)
11 $04 Occurrence count of 4
12 $24 Checksum
IID 00 is used to request additional information on a fault 500000070058008300BEC34DIID 00 - Special parameter Command
Table 10
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $01 CCM is the sending module
3 $00 IID 00
4 $07 Number of bytes
5 $00 Reply in ASCII format
6 $58 GSC number 1
7, 8 $00 $83 PID $0083 GSC Fault Log Request For Additional Data
9, 10, 11 $00 $BE $C3 More information requested on CID 190 FMI 3
12 $4D Checksum
IID 25 will contain the reply as PID $0084 5001250B58008400BEC303000C001102IID 25 - Single Parameter Read Response
Table 11
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $01 CCM is the sending module
3 $25 IID 25
4 $0B Number of bytes
5 $58 GSC number 1
6, 7 $00 $84 PID $0084 GSC Fault Log Response For Additional Data
8, 9 $00 $BE CID 190
10 $C3 More information on FMI 3
11 $03 Three occurrences of this fault
12, 13 $00 $0C First occurrence at 12 hours
14, 15 $00 $11 Last occurrence at 17 hours
16 $02 Checksum Monitoring Generator Phase
The following example shows how to select which generator phase the GSC monitors.
Use IID 34 to write the parameters of PID $F0B0: 500034050048F0B0007FIID 34 - Single Parameter Write Request
Table 12
Byte(s) Byte Contents Detailed Description
1 $50 Indicates M5X protocol
2 $00 User's PC is the sending module
3 $34 IID 34
4 $05 Number of bytes
5 $00 Reply in ASCII format
6 $58 GSC number 1
7, 8 $F0 $B0 PID $F0B0 Generator Phase Select
9 $00 Phase A-B Voltage, Phase A Current
10 $7F Checksum
IID 35 is the response from the CCM: 5001350458F0B0007EIID 35 - Single Parameter Write Response
Table