101603-8240 ZEXEL F 019 Z10 362 BOSCH INJECTION-PUMP ASSEMBLY f019z10362 1016038240 8943937530

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 019 Z10 362 f019z10362

ZEXEL 101603-8240 1016038240

ISUZU 8943937530 8943937530

Service parts 101603-8240 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6120

3. GOVERNOR 105931-9800

4. SUPPLY PUMP 105210-5110

5. AUTOM. ADVANCE MECHANIS 105643-0860

6. COUPLING PLATE 105661-1101

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-7183

11. Nozzle and Holder 8-94394-906-1

12. Open Pre:MPa(Kqf/cm2) 18.1(185)/22.1(225)

13. NOZZLE-HOLDER 105048-3883

14. NOZZLE 105017-3290

15. NOZZLE SET

Include in #1:

101402-4152 as _

101603-8240 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 362 f019z10362

ZEXEL 101603-8240 1016038240

ISUZU 8943937530 8943937530

Zexel num

Bosch num

Firm num

Name

101603-8240
101603-8241

F 019 Z10 362

8943937530 ISUZU

INJECTION-PUMP ASSEMBLY
6HE1-TC1 * 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 132424-0620

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)
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 3.5 3.45 3.55

Rack position
Point A R=A

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 12.7

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 97 95.4 98.6

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 265 265 265

Average injection quantity mm3/st. 8 6.7 9.3

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(12.7)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 97 96 98

Basic *

Fixing the lever *

Boost pressure kPa 26 26

Boost pressure mmHg 195 195

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 101 97.8 104.2

Fixing the lever *

Boost pressure kPa 26 26

Boost pressure mmHg 195 195

Injection quantity adjustment_05

Adjusting point C

Rack position R1-1.2

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 74.5 71.3 77.7

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 102 102 134

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 850 850 850

Rack position R1-1.2

Boost pressure kPa 5.3 4 6.6

Boost pressure mmHg 40 30 50

Boost compensator adjustment_02

Pump speed r/min 850 850 850

Rack position R1(12.7)

Boost pressure kPa 12.7 6 19.4

Boost pressure mmHg 95 45 145

Timer adjustment

Pump speed r/min 1175--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 1125

Advance angle deg. 0.3

Load 3/4

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 3.5 3 4

Load 4/4

Remarks
Finish

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)Adjust so that the boost compensator pushrod protrusion R = Ra at 0 boost. (4)Boost compensator stroke: BCL
----------
T1=J09 Ra=12+0.5mm BCL=1.2+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=35mm
----------
a=11deg+-5deg b=38deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=45mm
----------
a=12.5deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)- (5)Pump vertical direction (6)Direction of rotation (7)Pointer (8)Pointer stamping (9)Timing device stamping (10)Timing device (11)Stamp both at the same time as shown above. (12)Outside circumference of timing device (13)Secondary timing stamping position for the No. 1 cylinder's beginning of injection
----------
aa=12deg bb=0deg30min
----------
a=(160deg) b=0deg30min