Information injection-pump assembly
BOSCH
F 019 Z10 499
f019z10499
ZEXEL
101602-7610
1016027610
ISUZU
1156027940
1156027940
Rating:
Service parts 101602-7610 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
5-15300-103-2
12.
Open Pre:MPa(Kqf/cm2)
14.7(150)
15.
NOZZLE SET
Cross reference number
BOSCH
F 019 Z10 499
f019z10499
ZEXEL
101602-7610
1016027610
ISUZU
1156027940
1156027940
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 6-2-600
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
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
3.6
3.55
3.65
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
8.9
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
57.5
56
59
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the rack
*
Injection quantity adjustment_02
Adjusting point
-
Rack position
7.6+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
9.4
8.1
10.7
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK CAP: R1
(4)Set idle sub-spring
(5)Main spring setting
----------
K=7 R1=(17.5)mm
----------
----------
K=7 R1=(17.5)mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Set the speed at aa, set the stopper bolt
(2)Set the pump speed at bb.
(3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=18deg+-5deg b=3deg+-5deg c=4deg+-5deg
----------
aa=900r/min bb=750r/min
----------
a=18deg+-5deg b=3deg+-5deg c=4deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=2.5deg+-5deg b=46deg+-5deg
----------
----------
a=2.5deg+-5deg b=46deg+-5deg
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=20deg
----------
a=(90deg)
----------
aa=20deg
----------
a=(90deg)
Information:
Overview of Lubrication System
Flow of oilOil Pump, Relief Valve, and Oil Pressure Switch
Disassembly
Removal sequence and points to check on oil pump(1) Oil filter(2) Oil pump(3) Gasket(4) Oil pump cover(5) Inner rotor(6) Outer rotor (the inner and outer rotors from a rotor assembly)(7) O-ring(8) Oil pump body(9) Relief valve(10) Oil pressure switch Key Points For Disassembly(1) Oil Pump
Remove the oil pump (parts (3) through (8) in the above illustration) as an assembly.
Removing oil pump(2) Oil Pressure Switch
Remove the switch using the Oil Pressure Switch Socket Wrench (MD998054).
Removing oil pressure switchInspection and Repair
(1) Oil Pump
(a) Using a thickness gauge, measure the clearance between the outer rotor and pump body. If the measurement exceeds the limit, replace the rotor assembly.Unit: mm (in.)
Measuring outer rotor-to-pump body clearance(b) Using a thickness gauge, measure the clearance between the outer rotor and the inner rotor. If the measurement exceeds the limit, replace the rotor assembly.Unit: mm (in.)
Measuring outer rotor-to-inner rotor clearance(c) Using a thickness edge and a thickness gauge, measure the clearance between the rotors and pump cover. If the measurement exceeds the limit, replace either the rotors or the pump body.Unit: mm (in.)
Measuring clearance between rotors and pump cover(2) Oil Pressure Switch
(a) Connect a tester (set to the ohm range) between the terminal and body of the oil pressure switch. There should be no continuity. If there is continuity, the switch is faulty and should be replaced.
Inspecting oil pressure switch(b) Insert a thin rod into the oil hole in the switch body. When the rod is then pushed in gently, there should be continuity between the switch body and terminal. If there is no continuity, the switch is faulty and should be replaced.(c) apply an air pressure of 49 kPa {0.5 kgf/cm2) (7.1 psi) to the switch through the oil hole. If there is continuity, the switch is normal. Simultaneously, check for air leakage. Any air leakage means that the diaphragm is broken and, therefore, the switch should be replaced.
Inspecting oil pressure switchAssembly
Point to note during reassembly of oil pumpPerform assembly by following the disassembly sequence in reverse: Key Points For Reassembly
Oil Pressure Switch
(a) Install the switch using the Oil Pressure Switch Socket Wrench (MD998054).(b) Before installation, apply sealant to the threads of the switch. (Use either Hermeseal H1 or ThreeBond 1104).
Installing Oil Pressure Switch
(a) Avoid applying sealant excessively to prevent it from reaching the end of the threads.(b Never tighten the switch to a torque exceeding specification.
Flow of oilOil Pump, Relief Valve, and Oil Pressure Switch
Disassembly
Removal sequence and points to check on oil pump(1) Oil filter(2) Oil pump(3) Gasket(4) Oil pump cover(5) Inner rotor(6) Outer rotor (the inner and outer rotors from a rotor assembly)(7) O-ring(8) Oil pump body(9) Relief valve(10) Oil pressure switch Key Points For Disassembly(1) Oil Pump
Remove the oil pump (parts (3) through (8) in the above illustration) as an assembly.
Removing oil pump(2) Oil Pressure Switch
Remove the switch using the Oil Pressure Switch Socket Wrench (MD998054).
Removing oil pressure switchInspection and Repair
(1) Oil Pump
(a) Using a thickness gauge, measure the clearance between the outer rotor and pump body. If the measurement exceeds the limit, replace the rotor assembly.Unit: mm (in.)
Measuring outer rotor-to-pump body clearance(b) Using a thickness gauge, measure the clearance between the outer rotor and the inner rotor. If the measurement exceeds the limit, replace the rotor assembly.Unit: mm (in.)
Measuring outer rotor-to-inner rotor clearance(c) Using a thickness edge and a thickness gauge, measure the clearance between the rotors and pump cover. If the measurement exceeds the limit, replace either the rotors or the pump body.Unit: mm (in.)
Measuring clearance between rotors and pump cover(2) Oil Pressure Switch
(a) Connect a tester (set to the ohm range) between the terminal and body of the oil pressure switch. There should be no continuity. If there is continuity, the switch is faulty and should be replaced.
Inspecting oil pressure switch(b) Insert a thin rod into the oil hole in the switch body. When the rod is then pushed in gently, there should be continuity between the switch body and terminal. If there is no continuity, the switch is faulty and should be replaced.(c) apply an air pressure of 49 kPa {0.5 kgf/cm2) (7.1 psi) to the switch through the oil hole. If there is continuity, the switch is normal. Simultaneously, check for air leakage. Any air leakage means that the diaphragm is broken and, therefore, the switch should be replaced.
Inspecting oil pressure switchAssembly
Point to note during reassembly of oil pumpPerform assembly by following the disassembly sequence in reverse: Key Points For Reassembly
Oil Pressure Switch
(a) Install the switch using the Oil Pressure Switch Socket Wrench (MD998054).(b) Before installation, apply sealant to the threads of the switch. (Use either Hermeseal H1 or ThreeBond 1104).
Installing Oil Pressure Switch
(a) Avoid applying sealant excessively to prevent it from reaching the end of the threads.(b Never tighten the switch to a torque exceeding specification.