106671-9112 ZEXEL F 019 Z20 073 BOSCH INJECTION-PUMP ASSEMBLY f019z20073 1066719112

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 073 f019z20073

ZEXEL 106671-9112 1066719112

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Buy INJECTION-PUMP ASSEMBLY 106671-9112 zexel genuine, new aftermarket engine parts with delivery

Service parts 106671-9112 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106067-0420

3. GOVERNOR 105487-6741

4. SUPPLY PUMP 105207-1620

5. AUTOM. ADVANCE MECHANIS 105681-4200

6. COUPLING PLATE 105662-1420

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7680

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105031-4530

14. NOZZLE 105015-9850

15. NOZZLE SET

Include in #1:

106671-9112 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z20 073 f019z20073

ZEXEL 106671-9112 1066719112

Zexel num

Bosch num

Firm num

Name

106671-9112

F 019 Z20 073

DPICO

INJECTION-PUMP ASSEMBLY
Q 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 8-3-600

Overflow valve 131424-4420

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)
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 4.4 4.35 4.45

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 13.1

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 175 170.6 179.4

Basic *

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.1+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 30 25.6 34.4

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.1)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 175 173 177

Basic *

Fixing the lever *

Boost pressure kPa 104 104

Boost pressure mmHg 780 780

Injection quantity adjustment_04

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 80 160

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R2(R1-3. 1)

Boost pressure kPa 3.3 3.3 6.6

Boost pressure mmHg 25 25 50

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(13.1)

Boost pressure kPa 90.6 90.6 90.6

Boost pressure mmHg 680 680 680

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Load 4/4

Remarks
Beginning of advance.

Timer adjustment_02

Pump speed r/min 250--

Advance angle deg. 1.5 1 2

Load 0/4

Remarks
Start

Timer adjustment_03

Pump speed r/min 500--

Advance angle deg. 0 0 0

Load 4/4

Timer adjustment_04

Pump speed r/min 700

Advance angle deg. 0.5

Load 4/4

Timer adjustment_05

Pump speed r/min 1100

Advance angle deg. 2.5 2 3

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Boost compensator stroke: BCL (3)Damper spring setting
----------
BCL=3.1+-0.1mm
----------

Speed control lever angle

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

----------
a=(18deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=18deg+-5deg b=37deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa (2)Lever free and normal position (3)Stopper bolt setting
----------
aa=3.5-0.5mm
----------
a=38deg+-5deg b=38deg+7deg-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=6.8+-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=14deg
----------
a=(6deg)

Information:

3-Cylinder Diesel Theory and Operation
The KDW 1003 diesel engine has an indirect injection (IDI) fuel delivery system. The fuel injectors are a unit style injector located in the cylinder head and actuated by the camshaft.As the camshaft turns, the adjustable pushrod forces the high-pressure plunger into the injector. The unit injector is then pressurized to 14,000 to 15000 kPa (2030 to 2175 psi) before injection. This process is known as popping pressure. The injection even will take place between 11° and 13° (BTDC) before the piston reaches top dead center.Refer to the engine emissions tag on the engine or the service manual for proper injection timing specifications. Refer to the service manual for the injection timing tool and procedures.The unit injectors are supplied low-pressure fuel from the electric fuel pump in the fuel tank to the injection lines coming through a grommet in the cylinder head. This pressure is between 60 to 70 kPa (8.7 to 10 psi). Fuel supply is hose A and fuel return is hose BCommon Specifications
Compression ratio: 22.8 to 1
Compression: new engine cold 2760 to 3100 kPa (400 to 450 psi) or old engine at 2415 to 2760 kPa (350 to 400 psi)
Compression minimum: 1725 kPa (250 psi) (below this pressure, cylinder misfire will occur)
Compression readingtaken through the glow plug hole, 563-4356 Test Kit
Firing order: 1 - 3 - 2
Supply fuel pressure: 60 to 70 kPa (8.7 to 10 psi)
Popping pressure: 14,000 to 15000 kPa (2030 to 2175 psi)
Thermostat open temperature: 78 to 82 °C (172.4 to 179.6 °F)
Thermostat fully open: 95 °C (203 °F)
Coolant fan on at 100.5 °C (213 °F) and off at 95 °C (203 °F)
Engine oil capacity: approximately 2.8 L (3 qt)
Engine oil (recommended): 5W-50 Synthetic
Engine oil pressure switch minimum opening pressure 30 kPa (4.35 psi) (on valve cover) normally close switch
Engine oil pressure at 120 °C (248 °F): 108 kPa (15.6 psi) at idle speed (800 to 900 rpm)Glow Plug and Thermistor
The KDW 1003 engine uses glow plug temperature sensor, or a thermistor, to adjust glow plug on time. The glow plugs are in the cylinder head precombustion chamber and heat up to 816 °C (1500 °F) to assist with starting the engine. The sensor is in the thermostat housing. As the coolant temperature rises, the sensor resistance goes down.The glow plug controller/relay is a plug-in device above the battery. The glow plug controller/relay applies 12 volts DC to the glow plugs in the precombustion chambers to aid in cold starting. Heating time is determined by the ECT thermistor signal and will vary from 0 seconds (warm engine) to approximately 30 seconds (cold engine).
Illustration 1 g06469140
(1) Black wire
(2) Brown wire
(3) Red/Orange wire
(4) Violet/White wire
(5) Orange wire
(6) Pink wire
(7) White/Blue wireUse the following procedure to test the glow plug relay. You will need a multimeter for the procedure.Note: The test should take 15 to 35 minutes.
Using an appropriate multimeter, select DC volts and connect the black test lead to the black wire (1) and the red test lead to the red/orange