Information injection-pump assembly
BOSCH
F 019 Z10 385
f019z10385
ZEXEL
101607-6174
1016076174
Rating:
Service parts 101607-6174 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076952
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
14.
NOZZLE
Cross reference number
BOSCH
F 019 Z10 385
f019z10385
ZEXEL
101607-6174
1016076174
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
131424-8420
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)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Governor side NO.1
Governor 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
-
Rack position
12
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
85.1
82.5
87.7
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
9.5+-0.5
Pump speed
r/min
800
800
800
Each cylinder's injection qty
mm3/st.
10.8
9.2
12.4
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
85.1
84.1
86.1
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.85
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
99.9
95.9
103.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
91
81
101
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1100
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
2.5
2.5
3.5
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
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)RACK LIMIT
----------
T1=G43
----------
----------
T1=G43
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=18.5deg+-5deg b=(42deg)+-3deg
----------
----------
a=18.5deg+-5deg b=(42deg)+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection.
(2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position).
(3)Rack position = approximately ee.
(4)Free (at delivery)
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg
----------
aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13deg+-5deg
0000001501 MICRO SWITCH
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
1. Microswitch adjustment (OPEN type)
Confirm with the lever angle at full.
(1)Speed N1
(2)Rack position Ra
----------
N1=1675r/min Ra=8.5+-0.1mm
----------
----------
N1=1675r/min Ra=8.5+-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=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------
----------
V1=3.57+-0.02V V2f=3+0.05V V2i=1+0.1V
----------
0000001701 LEVER
(A) Idle
(B) Full speed
(C) Base lever
(D) Accelerator lever
(E) Accelerator lever delivery position
1. Measure speed lever angle
(1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------
----------
b=(42deg)+-3deg c=18.5deg+-5deg
----------
----------
b=(42deg)+-3deg c=18.5deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of timer's tooth at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=10deg
----------
a=(2deg)
----------
aa=10deg
----------
a=(2deg)
Information:
Repeat Steps 4 through 6 to remove (bleed) air from the rear table lift cylinder (not shown).
Open (CCW) hand pump control knob (11) to completely lower the DPF cleaner table. Close (CW) the hand pump control knob.
Illustration 38 g02728258
(28) Hydraulic Oil Level 51 to 102 mm (2.0 to 4.0 inch)
Check the oil level in the pump reservoir. Remove fill cap (13) located on the end cap of the hand pump. Hydraulic oil level (28) should be 51 to 102 mm (2.0 to 4.0 inch) from the bottom of the fill hole. Add high-grade hydraulic oil, if needed.Note: A clean wire tie can be used as a dipstick to measure the hydraulic oil level in the pump reservoir.Troubleshooting Guide
Table 3
Symptom Solution
Air dryer desiccant is a pinkish color. 1. Replace or regenerate the desiccant. Refer to ""Maintenance Section"".
Bursting does not occur. 1. Check display screen for error message.
2. Check power connection to burst valve solenoid.
Cabinet doors do not close correctly. 1. Look for damaged door hinges, seals, and latches.
2. Verify that vehicle sensors have been removed from DPF.
Cabinet doors open during burst process. 1. Verify that doors are correctly latched.
2. Look for damage to door latches.
3. Check seals between DPF and adapters.
Clamping force cannot be obtained. 1. Look for hydraulic fluid leaks.
2. Check fluid level in hydraulic pump. Refer to ""Maintenance Section"".
Clamping force does not hold. 1. Upon initial clamping, it is possible for clamp load to drop
689 to 1379 kPa (99.9 to 200.0 psi) within the first minute, due to temperature effects. After reclamping, the drop should be virtually zero.
2. Look for hydraulic fluid leaks.
Display screen is blank. 1. Verify that machine is ON, plugged into an outlet, and power is available to the outlet.
2. Reset circuit breakers located on left side of control cabinet.
DPF does not line up correctly on the table. 1. Verify that correct adapters are being used.
2. Verify DPF is correctly seated on to lower adapter.
DPF is damaged after cleaning process. 1. Check DPFs for damage before cleaning.
2. Look for damage on adapters.
3. Verify that correct cleaning protocol was entered into machine.
DPF is not cleaned. 1. Check orientation of DPF. Refer to ""General Information"" Section.
2. Verify that correct cleaning protocol was entered into machine.
3. Look for other DPF conditions that may prevent successful cleaning.