101606-9990 ZEXEL F 019 Z20 000 BOSCH INJECTION-PUMP ASSEMBLY f019z20000 1016069990

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 000 f019z20000

ZEXEL 101606-9990 1016069990

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107492-1032 as _

Cross reference number

BOSCH F 019 Z20 000 f019z20000

ZEXEL 101606-9990 1016069990

Zexel num

Bosch num

Firm num

Name

101606-9990

F 019 Z20 000

DPICO

INJECTION-PUMP ASSEMBLY
6D22 Q

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 131424-5120

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.5 4.45 4.55

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 9.1

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 98 95.5 100.5

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 450 450 450

Each cylinder's injection qty mm3/st. 20 17 23

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9.1)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 98 97 99

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point F

Rack position 8+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 30 27 33

Fixing the rack *

Remarks
(check)

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1150

Advance angle deg. 4.5 4 5

Remarks
Finish

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 (N = N1) (3)Set at delivery (4)Damper spring setting
----------
SXL=(R1+0.2)+0.2mm N1=500r/min
----------

Speed control lever angle

F:Full speed
----------

----------
a=(1deg)+-5deg

0000000901

F:Full load I:Idle (1)Set at delivery (2)Stopper bolt setting
----------

----------
a=25deg+-5deg b=25.5deg+-3deg c=1deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side
----------

----------
a=54deg+-5deg b=71deg+-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=7.3+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=19deg
----------
a=(7deg)

Information:

(1) 7S7144 Spring for valves (new): Length under test force ... 44.86 mm (1.766 in)Test force ... 257 25 N (57.7 4.5 lb)Free length after test ... 52.07 mm (2.050 in)Outside diameter ... 35.21 mm (1.386 in)103-2454 Spring for valves (new): Length under test force ... 44.93 mm (1.769 in)Test force ... 379 19 N (85.2 4.3 lb)Free length after test ... 54.37 mm (2.141 in)Outside diameter ... 35.56 mm (1.400 in)(2) Height to top of valve guide ... 22.23 0.25 mm (.875 .010 in)(3) Diameter of valve stem (new) ... 9.441 0.008 mm (.3717 .0003 in) Use again minimum diameter ... 9.408 mm (.3704 in)Bore in valve guide with guide installed in the head.Minimum permissible (new) ... 9.456 mm (.3723 in)Maximum permissible (worn) ... 9.581 mm (.3772 in)(4) Valve lip thickness: Exhaust Valve Use again minimum ... 2.69 mm (.106 in)Intake Valve Use again minimum ... 2.69 mm (.106 in)(5) Diameter of valve head: Exhaust valve ... 48.16 0.13 mm (1.896 .005 in)Intake valve ... 51.31 0.13 mm (2.020 .005 in)(6) Angle of valve face ... 29 1/4 1/4 degrees (7) Depth of bore in head for valve seat insert ... 12.28 0.13 mm (.483 .005 in)(8) Diameter of valve seat insert for exhaust valve ... 50.889 0.013 mm (2.0035 .0005 in) Bore in head for valve seat insert for exhaust valve ... 50.813 0.030 mm (2.0005 .0012 in)Diameter of valve seat insert for intake valve ... 52.032 0.013 mm (2.0485 .0005 in)Bore in head for valve seat insert for intake valve ... 51.956 0.030 mm (2.0455 .0012 in)(9) Angle of face of valve seat insert ... 30 1 degrees(10) Maximum permissible width of valve seat (intake and exhaust) ... 1.93 mm (.076 in) Minimum permissible width of valve seat (intake and exhaust) ... 1.14 mm (.045 in)(11) Dimension from top of closed valve to face of head: Minimum permissible dimension for 6N9916 Exhaust Valve ... 0.66 mm (.026 in)Minimum permissible dimension for 2W2620 Intake Valve ... 0.15 mm (.006 in)(12) Outside diameter of the face of the valve seat insert: Exhaust seat ... 46.02 mm (1.812 in)Maximum permissible, exhaust seat ... 47.29 mm (1.862 in)Intake seat ... 49.28 mm (1.940 in)Maximum permissible, intake seat ... 50.55 mm (1.990 in)(13) Angle to grind seat face of the insert to get a reduction of maximum seat diameter ... 15 degrees