Information injection-pump assembly
BOSCH
F 019 Z10 650
f019z10650
ZEXEL
106873-2490
1068732490
Rating:
Service parts 106873-2490 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
17.7(180)/24.5(250)
15.
NOZZLE SET
Include in #1:
106873-2490
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 019 Z10 650
f019z10650
ZEXEL
106873-2490
1068732490
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
131424-4620
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-2-7-3-
4-5-6-8
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
10.7
Pump speed
r/min
650
650
650
Each cylinder's injection qty
mm3/st.
147.3
142.9
151.7
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.8+-0.5
Pump speed
r/min
225
225
225
Each cylinder's injection qty
mm3/st.
19
16.1
21.9
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.7)
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
147.3
146.3
148.3
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.4
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
136.4
134.4
138.4
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
173
153
193
Fixing the lever
*
Remarks
After startup boost setting
After startup boost setting
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Excess fuel setting for starting: SXL
(3)Damper spring setting
----------
SXL=10.9+-0.1mm
----------
----------
SXL=10.9+-0.1mm
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(8.8)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=8.8+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
----------
----------
a=20.5deg+-5deg
----------
----------
a=20.5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=25.5deg+-3deg
----------
----------
a=10deg+-5deg b=25.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa, stopper bolt setting
----------
aa=4.3-0.5mm
----------
a=10.5deg+-5deg b=55deg+7deg-5deg
----------
aa=4.3-0.5mm
----------
a=10.5deg+-5deg b=55deg+7deg-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=325r/min Ra=6.3+-0.1mm
----------
----------
N1=325r/min Ra=6.3+-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=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
37. Remove races (70) and (72) and bearing (71) from the camshaft in the fuel injection pump housing. Assemble Governor
1. Put the fuel injection pump housing in position on tool (A). Install race (3), bearing (2) and race (1) on the end of the camshaft in the fuel injection pump housing. 2. Put flyweights (5) in position on carrier assembly (4), and install dowels (6) to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.230 mm (.0004 to .0090 in) end play. 3. Install governor shaft (7) on carrier assembly (4). 4. Install dowel (8) in governor shaft (7), and slide carrier assembly (4) down on the governor shaft until dowel (8) fits into the slot in the carrier assembly.5. Install carrier assembly (4) on the end of the camshaft. 6. Install race (12), bearing (11), race (10) and ring (9) on riser (13). 7. Install riser (13) and spring (14), if equipped, on the governor shaft. 8. Install spool (18) and ring (19) on seat (17), and use tool (B) to install ring (20) to hold them in position.9. Install seat (17) on spring (16) and spring (16) on shield (15). 10. Install dashpot assembly (21) on the governor shaft. 11. Install ring (22) in the groove on the governor shaft. Install sleeve (23), spring (25), the sleeve and bearing (24) on the governor shaft. 12. Use tool (C) to hold spring (25) under compression, and install the ring in the groove on the governor shaft. 13. Install O-ring seal (26) on sleeve (27). Install piston (29) and sleeve (27) in the governor servo as shown.14. Install valve (28) in the governor servo as shown. 15. Install lockring (33) in the groove near the center of valve (28). Put sleeve (34), spring (broken link spring) (35) and seat (36) in position on valve (28), and install lockring (37) to hold them in place. 16. Put governor servo (30) in position on the fuel injection pump housing with piston (29) engaged over the rack. Make sure the lever is engaged in the (slot) groove of riser (13). 17. If dowel (43) was removed, install it in block (44) 31 0.5 mm (1.22 .02 in) above the outside surface of the block.18. Install bolt (45) in block (44) and spring (38) on bolt (45).19. Install stop screw (40) and the locknut on collar (42). Install power setting screw (41) and the locknut on the collar.20. Install collar (42) on bolt (45). Make an alignment of the hole in the collar with the notch in bolt (45), and install bolt (39). 21. If the dowels that align block (44) with the front governor housing were removed, install them 4.0 0.5 mm (.16 .02 in) above the outside surface of the front governor housing.22. Put block (44) in position on the front governor housing with the holes in the block in alignment with dowels in the front governor
1. Put the fuel injection pump housing in position on tool (A). Install race (3), bearing (2) and race (1) on the end of the camshaft in the fuel injection pump housing. 2. Put flyweights (5) in position on carrier assembly (4), and install dowels (6) to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.230 mm (.0004 to .0090 in) end play. 3. Install governor shaft (7) on carrier assembly (4). 4. Install dowel (8) in governor shaft (7), and slide carrier assembly (4) down on the governor shaft until dowel (8) fits into the slot in the carrier assembly.5. Install carrier assembly (4) on the end of the camshaft. 6. Install race (12), bearing (11), race (10) and ring (9) on riser (13). 7. Install riser (13) and spring (14), if equipped, on the governor shaft. 8. Install spool (18) and ring (19) on seat (17), and use tool (B) to install ring (20) to hold them in position.9. Install seat (17) on spring (16) and spring (16) on shield (15). 10. Install dashpot assembly (21) on the governor shaft. 11. Install ring (22) in the groove on the governor shaft. Install sleeve (23), spring (25), the sleeve and bearing (24) on the governor shaft. 12. Use tool (C) to hold spring (25) under compression, and install the ring in the groove on the governor shaft. 13. Install O-ring seal (26) on sleeve (27). Install piston (29) and sleeve (27) in the governor servo as shown.14. Install valve (28) in the governor servo as shown. 15. Install lockring (33) in the groove near the center of valve (28). Put sleeve (34), spring (broken link spring) (35) and seat (36) in position on valve (28), and install lockring (37) to hold them in place. 16. Put governor servo (30) in position on the fuel injection pump housing with piston (29) engaged over the rack. Make sure the lever is engaged in the (slot) groove of riser (13). 17. If dowel (43) was removed, install it in block (44) 31 0.5 mm (1.22 .02 in) above the outside surface of the block.18. Install bolt (45) in block (44) and spring (38) on bolt (45).19. Install stop screw (40) and the locknut on collar (42). Install power setting screw (41) and the locknut on the collar.20. Install collar (42) on bolt (45). Make an alignment of the hole in the collar with the notch in bolt (45), and install bolt (39). 21. If the dowels that align block (44) with the front governor housing were removed, install them 4.0 0.5 mm (.16 .02 in) above the outside surface of the front governor housing.22. Put block (44) in position on the front governor housing with the holes in the block in alignment with dowels in the front governor