101491-0553 ZEXEL F 019 Z10 816 BOSCH INJECTION-PUMP ASSEMBLY f019z10816 1014910553

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 019 Z10 816 f019z10816

ZEXEL 101491-0553 1014910553

Service parts 101491-0553 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-8720

3. GOVERNOR 105931-8060

4. SUPPLY PUMP 105210-5140

5. AUTOM. ADVANCE MECHANIS 105671-0160

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5122

11. Nozzle and Holder 8-97021-703-1

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

13. NOZZLE-HOLDER 105048-3352

14. NOZZLE

105017-0610

15. NOZZLE SET

Include in #1:

101402-3700 as _

101491-0553 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 816 f019z10816

ZEXEL 101491-0553 1014910553

Zexel num

Bosch num

Firm num

Name

101491-0553
101491-0554

F 019 Z10 816

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 131424-4920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-3-4-2

Pre-stroke mm 3.8 3.75 3.85

Rack position
After adjusting injection quantity. R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 12.6

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 70.7 69.1 72.3

Max. variation between cylinders % 0 -2.5 2.5

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 325 325 325

Average injection quantity mm3/st. 13.3 12 14.6

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.6)

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 70.7 69.7 71.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1750 1750 1750

Average injection quantity mm3/st. 79.9 75.9 83.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 92 92 124

Fixing the lever *

Timer adjustment

Pump speed r/min (1475)

Advance angle deg. 0.3

Remarks
Measure the actual speed.

Timer adjustment_02

Pump speed r/min (1775)

Advance angle deg. 4.5 4 5

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)At delivery (at R = A, N = N1)
----------
T1=F44 N1=100r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Set the idle side stopper bolt so that speed = bb and rack position = cc (at delivery). (3)Stopper bolt set position 'H'
----------
aa=50mm bb=100r/min cc=R1(12.6)mm
----------
a=(23.5deg) b=27.5deg+-5deg c=34deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=45deg+-5deg b=29deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131154-1820 ST=A260 L1=1mm L2=3.8+-0.05mm a1=+-14% a2=+-2.5%
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'CC' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(100deg)