Information injection-pump assembly
BOSCH
F 019 Z10 526
f019z10526
ZEXEL
106671-4841
1066714841
Rating:
Service parts 106671-4841 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
14.
NOZZLE
15.
NOZZLE SET
Include in #1:
106671-4841
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 526
f019z10526
ZEXEL
106671-4841
1066714841
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-4420
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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)
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
4.7
4.65
4.75
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
10.4
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
148
146
150
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Boost pressure
kPa
56
56
Boost pressure
mmHg
420
420
Injection quantity adjustment_02
Adjusting point
B
Rack position
11
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
154.5
151.5
157.5
Max. variation between cylinders
%
0
-3
3
Fixing the lever
*
Boost pressure
kPa
56
56
Boost pressure
mmHg
420
420
Injection quantity adjustment_03
Adjusting point
F
Rack position
5.2+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
14.5
13
16
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_04
Adjusting point
G
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
165
160
170
Fixing the lever
*
Boost pressure
kPa
56
56
Boost pressure
mmHg
420
420
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
500
500
500
Rack position
8.7
Boost pressure
kPa
22.7
20.7
24.7
Boost pressure
mmHg
170
155
185
Boost compensator adjustment_02
Pump speed
r/min
500
500
500
Rack position
10.4
Boost pressure
kPa
42.7
42.7
42.7
Boost pressure
mmHg
320
320
320
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
3
2.5
3.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)RACK LIMIT
(5)Boost compensator stroke: BCL
(6)Damper spring setting
(7)Microswitch adjustment unnecessary.
----------
RT=1 TH=2.9mm BCL=1.7+-0.1mm
----------
----------
RT=1 TH=2.9mm BCL=1.7+-0.1mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=7deg+-5deg
----------
----------
a=7deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=34deg+-3deg
----------
----------
a=10deg+-5deg b=34deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=40deg+-5deg b=73deg+-5deg
----------
----------
a=40deg+-5deg b=73deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position for the No. 6 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
Information:
Cruise Control On/Off Input Circuit
The cruise control (CC) and power take-off (PTO) ON/OFF input is an ordinary switch. With this switch in the ON position, it is possible to "activate" the cruise control or power take-off mode if other ECM programmed conditions are met.With this switch "open" (or OFF), the input line to the ECM will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the ECM will go to 0 volts (ground).Cruise Control Set/Resume Input Circuit
The cruise control and power take-off set/resume is provided by a three position switch. The switch is used to SET vehicle speed or engine rpm. The function of each position of the switch is as follows:1) CENTER POSITION, the set/resume switch is "open" and all inputs are inactive.2) SET POSITION, after the switch is moved to the SET position and released, the ECM will maintain the existing engine rpm (determining vehicle speed) when the switch was released. If the engine is held in the SET position, the ECM will gradually increase engine rpm (determining vehicle speed) until the switch is released.3) RESUME POSITION, if cruise is deactivated by application of the clutch or service brake, and the switch is then moved to the RESUME position and released, the cruise (PTO) mode is reactivated to the last setting. If the switch is held in the RESUME position, the ECM will gradually decrease engine rpm (determining vehicle speed) until the switch is released.With this switch "open" (or OFF), the input line to the ECM will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the ECM will go to 0 volts (ground).Vehicle Switches Input Circuits
The brake switch is used to deactivate the cruise or PTO modes when the vehicle service brakes are applied. The brake switch is also used to activate the retarder enable output if the service brakes are applied while in cruise mode.The clutch switch is used to deactivate the cruise or PTO modes when the clutch pedal is pressed. The clutch switch is used to DEACTIVATE the retarder enable circuit.With this switch "open" (or OFF), the input line to the EMC will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the EMC will go to 0 volts (ground).Fuel Pressure Input Circuit
Fuel pressure is monitored after the filter by the fuel pressure sensor which is located on the fuel filter housing. The 5 Volt DC operating voltage for this sensor is supplied by the ECM. The output of the fuel pressure sensor is a .5 to 4.5 Volts DC signal. The voltage is dependent upon fuel pressure and is interpreted by the ECM as fuel pressure. If fuel pressure is less than 445 kPa (65 psi) at rated rpm, the "check engine" light is turned on.Engine Electrical System
The electrical system can have three separate circuits: the charging circuit, the starting circuit and the low amperage circuit. Some of the electrical system components are
The cruise control (CC) and power take-off (PTO) ON/OFF input is an ordinary switch. With this switch in the ON position, it is possible to "activate" the cruise control or power take-off mode if other ECM programmed conditions are met.With this switch "open" (or OFF), the input line to the ECM will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the ECM will go to 0 volts (ground).Cruise Control Set/Resume Input Circuit
The cruise control and power take-off set/resume is provided by a three position switch. The switch is used to SET vehicle speed or engine rpm. The function of each position of the switch is as follows:1) CENTER POSITION, the set/resume switch is "open" and all inputs are inactive.2) SET POSITION, after the switch is moved to the SET position and released, the ECM will maintain the existing engine rpm (determining vehicle speed) when the switch was released. If the engine is held in the SET position, the ECM will gradually increase engine rpm (determining vehicle speed) until the switch is released.3) RESUME POSITION, if cruise is deactivated by application of the clutch or service brake, and the switch is then moved to the RESUME position and released, the cruise (PTO) mode is reactivated to the last setting. If the switch is held in the RESUME position, the ECM will gradually decrease engine rpm (determining vehicle speed) until the switch is released.With this switch "open" (or OFF), the input line to the ECM will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the ECM will go to 0 volts (ground).Vehicle Switches Input Circuits
The brake switch is used to deactivate the cruise or PTO modes when the vehicle service brakes are applied. The brake switch is also used to activate the retarder enable output if the service brakes are applied while in cruise mode.The clutch switch is used to deactivate the cruise or PTO modes when the clutch pedal is pressed. The clutch switch is used to DEACTIVATE the retarder enable circuit.With this switch "open" (or OFF), the input line to the EMC will go to approximately 5 volts. With the switch "closed" (or ON), the input line to the EMC will go to 0 volts (ground).Fuel Pressure Input Circuit
Fuel pressure is monitored after the filter by the fuel pressure sensor which is located on the fuel filter housing. The 5 Volt DC operating voltage for this sensor is supplied by the ECM. The output of the fuel pressure sensor is a .5 to 4.5 Volts DC signal. The voltage is dependent upon fuel pressure and is interpreted by the ECM as fuel pressure. If fuel pressure is less than 445 kPa (65 psi) at rated rpm, the "check engine" light is turned on.Engine Electrical System
The electrical system can have three separate circuits: the charging circuit, the starting circuit and the low amperage circuit. Some of the electrical system components are