101693-9402 ZEXEL F 019 Z10 841 BOSCH INJECTION-PUMP ASSEMBLY f019z10841 1016939402 16713z5878

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 841 f019z10841

ZEXEL 101693-9402 1016939402

NISSAN-DIESEL 16713Z5878 16713z5878

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Service parts 101693-9402 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-3830

3. GOVERNOR 105921-4561

4. SUPPLY PUMP 105220-7060

5. AUTOM. ADVANCE MECHANIS 105672-0160

6. COUPLING PLATE 105661-0391

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6350

11. Nozzle and Holder 16600Z5601

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105031-4650

14. NOZZLE

105015-8760

15. NOZZLE SET

Include in #1:

101606-6660 as _

101693-9402 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 841 f019z10841

ZEXEL 101693-9402 1016939402

NISSAN-DIESEL 16713Z5878 16713z5878

Zexel num

Bosch num

Firm num

Name

101693-9402

F 019 Z10 841

16713Z5878 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FE6T * 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 134424-1520

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.9 3.85 3.95

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 12.7

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 83 81 85

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.6 7.8 11.4

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.7)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 83 82 84

Basic *

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.05

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 93.5 90.3 96.7

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Injection quantity adjustment_05

Adjusting point C

Rack position R2(R1-0. 1)

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 77.5 74.3 80.7

Fixing the lever *

Boost pressure kPa 21.3 21.3

Boost pressure mmHg 160 160

Injection quantity adjustment_06

Adjusting point D

Rack position R2-0.5

Pump speed r/min 550 550 550

Average injection quantity mm3/st. 66.5 64.5 68.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 84 84 104

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position R2-0.5

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R2(R1-0. 1)

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

Timer adjustment

Pump speed r/min -

Advance angle deg. 0.5

Remarks
Measure the actual speed.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 3 3 3

Remarks
Measure the actual speed, stop

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 (4)Boost compensator stroke: BCL
----------
T1=F07 BCL=0.5+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Bottom lever
----------
aa=39mm
----------
a=26.5deg+-5deg b=44deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=40deg+-5deg

0000001501 LEVER

(a) Speed lever (B) Accelerator lever (C) Accelerator lever stopper bolt (D) Full speed side (E) idle side 1. Accelerator lever setting method With speed lever at idle position, from point S contact Back off the accelerator lever stopper bolt L and set. (Turn bolt L turns and set.)
----------

----------
r=36mm L=1+0.5mm

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

1. Drain the coolant from the radiator. 2. Remove bolts (1) and grill (2). 3. Remove bolts (5) and fan guard (3). Remove bolts (6) and support bracket (4). Remove the enclosure group top panel (7).4. Remove the bolts holding the enclosure group side panels. Remove the side panels.5. Loosen the hose clamps on the upper and lower radiator hoses. Disconnect the radiator hoses from the radiator. 6. Use tooling (A) and attach a hoist to radiator (8). Remove the lower bolts holding the radiator to the base. Remove radiator (8). The weight of the radiator is 73 kg (161 lb.). The following steps are for the installation of the radiator.7. Use a hoist to install the radiator on the base. Install the bolts. Remove the hoist and tooling (A) from the radiator.8. Connect the upper and lower radiator hoses to the radiator. Tighten the hose clamps.9. Install the enclosure group side panels.10. Install the enclosure group top panel. Install the grill and the fan guard.11. Fill the radiator with coolant to the correct level. See the Maintenance Manual.Remove And Install Radiator And Radiator Guard (Prime)
1. Drain the coolant from the radiator. 2. Loosen hose clamps (4) and (5). Disconnect tube (1) from hose (6). Rotate tube (1) 180° for clearance. Remove bolts (2) from support arms (3). 3. Remove eight bolts (7) holding fan guard (8) to the radiator guard. 4. Install tool (A) and a hoist to the radiator. 5. Remove four bolts (10) that fasten the lower radiator elbow to the radiator. Separate the elbow from the radiator. Remove bolt (11) from the crankcase vent hose clamp.Remove four mounting bolts (9). Remove the radiator and radiator guard. The weight of the radiator and radiator guard is 250 Kg (550 lb.). The following steps are for the installation of the radiator and radiator guard.6. Use a hoist to put the radiator and radiator guard in position on the base. Install four mounting bolts (9). Remove the hoist and tool (A).7. Install the gasket and lower radiator elbow (12) to the radiator. Install bolts (10). Install bolt (11) and the clamp to hold the crankcase vent hose in place.8. Install bolts (7) to hold fan guard (8) in position.9. Connect tube (1) to hose (6) and tighten hose clamps (4) and (5). Install bolts (2) to secure control arms (3) to the radiator guard.10. Fill the radiator with coolant to the correct level. See the Maintenance Manual.Disassemble And Assemble Radiator
Start By:a. remove radiator and radiator guard **The radiator can be disassembled and assembled without removing the radiator and guard. 1. Remove eighteen bolts (2) and remove four plates (4). Remove four bolts, block off plate (1) and the gasket. Remove four bolts, upper radiator hose adapter (3) and the gasket. 2. Loosen four bolts (7). Disconnect tube assemblies (5) and (8). Remove four bolts (9) and remove coolant level switch if applicable. 3. Remove eleven bolts (11) and remove overflow tube (10), crankcase vent tube clamp (13)