101607-6240 ZEXEL F 019 Z10 388 BOSCH INJECTION-PUMP ASSEMBLY f019z10388 1016076240

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 388 f019z10388

ZEXEL 101607-6240 1016076240

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Service parts 101607-6240 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8470

3. GOVERNOR 105931-9640

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105672-5150

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7053

11. Nozzle and Holder ME076953

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

13. NOZZLE-HOLDER 105041-3031

14. NOZZLE 105015-9151

15. NOZZLE SET

Include in #1:

101607-6240 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-6901 as _

Cross reference number

BOSCH F 019 Z10 388 f019z10388

ZEXEL 101607-6240 1016076240

Zexel num

Bosch num

Firm num

Name

101607-6240
101607-6241

F 019 Z10 388

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 12.3

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 101.8 98.7 104.9

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 600 600 600

Each cylinder's injection qty mm3/st. 11.5 9.8 13.2

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 101.8 100.8 102.8

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1

Pump speed r/min 1350 1350 1350

Average injection quantity mm3/st. 117.9 113.9 121.9

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 4)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 92.6 88.6 96.6

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_06

Adjusting point E

Rack position R1+0.7

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 113.5 109.5 117.5

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R2-0.75

Boost pressure kPa 3.3 2 4.6

Boost pressure mmHg 25 15 35

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2(R1-0. 4)

Boost pressure kPa 22.7 22.7 22.7

Boost pressure mmHg 170 170 170

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1340

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Boost compensator stroke: BCL
----------
T1=H52 BCL=0.75+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=33deg+-5deg b=42deg+-3deg

Stop lever angle

N:Pump normal 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).
----------
aa=1350r/min bb=7-0.5mm cc=275r/min dd=(8)mm
----------
a=25deg+-5deg b=27deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

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=11deg
----------
a=(1deg)

Information:

Monitor
Illustration 1 g00856663
(1) Display (2) Indicators (3) Bezel With Stud Mounting (Standard NEMA Type 4)Connectors
Illustration 2 g00856664
(4) I/O Card (5) CPU Card (6) Shared PCI/ISA Expansion Slot (7) Serial Port 1 (DB9) (8) Backlight Dimming Control (9) PCI Slot (10) Video Port (HD-15) (11) Ethernet Connection (RJ45) (12) Parallel Port (DB25) (13) 2 USB Ports (14) 3.5" Internal Hard Drive (15) PS/2 Keyboard Connector (Mini DIN) (16) 3.5" Floppy Drive (17) PS/2 Mouse Connector (Mini DIN) (18) Cooling Fan and Filter (Bottom)Indicators
The following tables describe the indicators on the monitor. The labels for the indicators are symbols.
Illustration 3 g00856666
Diagnostic Indicator
Table 1
Position Color Description
Left Red Diagnostics The diagnostic indicator shows when one of the following conditions exists:Over Temperature - The temperature inside of the monitor enclosure is above the defined threshold.Fan Sensor - The system fan is not operating within the defined thresholds.Voltage - The voltages are not within the specifications.Refer to Troubleshooting, "Diagnostic Indicator Is On - Troubleshoot" for information on resolving diagnostic conditions.
Illustration 4 g00856667
Hard Drive Access Indicator
Table 2
Position Color Description
Center Green Hard Drive Access
Illustration 5 g00856668
Power On Indicator
Table 3
Position Color Description
Right Green Power On Backlight Dimming Control
Use the backlight dimming control (8) in order to vary the screen lighting for optimum viewing.Turn the control clockwise in order to increase the brightness of the display. Turn the control counterclockwise in order to dim the display backlight.