101609-9060 ZEXEL F 019 Z20 035 BOSCH INJECTION-PUMP ASSEMBLY f019z20035 1016099060

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 035 f019z20035

ZEXEL 101609-9060 1016099060

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104278-3060 as _

Cross reference number

BOSCH F 019 Z20 035 f019z20035

ZEXEL 101609-9060 1016099060

Zexel num

Bosch num

Firm num

Name

101609-9060

F 019 Z20 035

DPICO

INJECTION-PUMP ASSEMBLY
6D16 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 131424-5520

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 3.8 3.75 3.85

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 A

Rack position 9.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 77 76 78

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.6+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 15 13.5 16.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 71 61 81

Fixing the lever *

Rack limit *

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 LIMIT
----------
K=16
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=(14deg)+-5deg b=(25deg)+-5deg c=35deg+-3deg

Stop lever angle

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

----------
a=2.5deg+-5deg b=53deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of coupling's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(2deg)

Information:

1. Disconnect air line (1) from the fuel ratio control.2. Remove wire seal (4) from the bolts.3. Remove bolts (3) that hold fuel ratio control (2).4. Remove the fuel ratio control by pulling down and out from the collar. The following steps are for the installation of the fuel ratio control.5. Put fuel ratio control (2) in position on the governor. Make sure the valve head of the fuel ratio control is connected in the groove of the collar.6. Install bolts (3) that hold the fuel ratio control to the governor. Connect air line (1) to the fuel ratio control.7. To make an adjustment to the fuel ratio control, see the topic "Governor Adjustment For The Air Fuel Ratio Control" in, Testing & Adjusting Manual SENR6471.8. Install wire seal (4) on the bolts with Tool (A).Disassemble & Assemble Fuel Ratio Control
Start By:a. remove fuel ratio control 1. Put Tool (A) in a vise so that the station being used is not over the vise jaw. Place the fuel ratio control over the pins in Tool (A). Remove bolts (3) and remove cover (26) and gasket (24).
There is spring force behind cover (7). Hold cover (7) in position, and slowly remove the bolts that hold it to release the spring force.
2. Remove bolts (6). Remove cover (7) from housing (10).3. Remove nut (5) and stop (4) from cover (7).4. Remove spring (8), washer (9) and diaphragm (21) from retainer (25). Remove retainer (25) from housing (10).5. Remove tube (1) from the end of extension (19). Remove nut (2) from extension (19) and remove the extension from retainer (25). Remove valve (16), spring (22) and O-ring seal (23) from the extension.6. Remove spring (20), retainer (18) and spring (17) from housing (10).7. Remove piston (12) and valve assembly (14) from the housing.8. Use Tool (B) and remove snap ring (13) and washer (15) from the valve assembly. Remove piston (12) from the valve assembly.9. Remove seal (11) from piston (12).10. If necessary, remove the stem portion from valve assembly (14).11. Clean and inspect all parts. Make a replacement of all parts that are worn and damaged. The following steps are for the assembly of the fuel ratio control.12. If removed during disassembly, assemble the stem portion of valve assembly (14) on the valve using 9S3265 Retaining Compound.13. Lubricate seal (11) lightly with the lubricant being sealed. Put seal (11) on piston (12) and put piston (12) on valve assembly (14).14. Put washer (15) in position on the valve assembly and use Tool (B) to install snap ring (13) on the valve assembly.15. Place housing (10) on Tool (A), and put Tool (C) into the bore of the housing. Lubricate Tool (C) with clean engine oil.16. Push piston (12) into position with a smooth swift motion. Remove Tool (C) from the housing. Place spring (17), retainer (18) and spring (20) in housing (10).17. Put O-ring seal (23) on extension (19). Put spring (22) and valve (16) in position on the