106671-9420 ZEXEL F 019 Z20 083 BOSCH INJECTION-PUMP ASSEMBLY f019z20083 1066719420

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 083 f019z20083

ZEXEL 106671-9420 1066719420

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Cross reference number

BOSCH F 019 Z20 083 f019z20083

ZEXEL 106671-9420 1066719420

Zexel num

Bosch num

Firm num

Name

106671-9420

F 019 Z20 083

DPICO

INJECTION-PUMP ASSEMBLY
H100 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 134424-1420

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 1-4-2-6- 3-5

Pre-stroke mm 4 3.94 4

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 10.2

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 136 134 138

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_02

Adjusting point C

Rack position 6.3+-0.5

Pump speed r/min 260 260 260

Average injection quantity mm3/st. 8 5 11

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 130 140

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R1(8.5)

Boost pressure kPa 20 18.7 21.3

Boost pressure mmHg 150 140 160

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 10

Boost pressure kPa 46.7 46.7 46.7

Boost pressure mmHg 350 350 350

Timer adjustment

Pump speed r/min 765--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 715

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 850

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Microswitch not operating at delivery. (3)Set idle at point K (N = N1, R = R1) and confirm that the injection quantity does not exceed Q1 at point J (N = N2). (4)RACK LIMIT (5)Boost compensator stroke: BCL (6)Damper spring setting (7)Rack difference between N = N3 and N = N4 (8)Boost compensator cancel stroke: BSL
----------
N1=300r/min R1=6.3mm N2=1150r/min Q1=3mm3/st BCL=1.5+-0.1mm N3=1150r/min N4=700r/min BSL=2.2mm
----------

Speed control lever angle

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

----------
a=4deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=65mm
----------
a=22deg+-5deg b=23.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=30mm
----------
a=64deg+-5deg b=44deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

Table 7
464-8400 Air Lines Gp
Quantity Part Number Part Name
4 204-7562 Gasket
2 221-6861 Bellows As
2 227-4056 Gasket
1 386-7449 Housing
1 452-0270 Bracket
1 457-9114 Bracket
1 457-9115 Bracket
1 464-8144 Air Shutoff Gp
1 485-3715 Support
1 485-3716 Support
12 032-3237 Spacer
2 0L-1352 Bolt
8 0S-1587 Bolt
6 0S-1619 Bolt
20 118-0275 Washer
8 1A-1460 Bolt
4 1D-4609 Bolt
16 1F-7958 Full Nut
32 1K-6872 Locknut
4 2S-3567 Bolt
2 3E-4353 Hard Washer
64 3H-7654 Hard Washer
16 5J-4715 Washer
4 5P-6652 Washer
16 5P-8245 Hard Washer
2 8F-6350 Bolt
2 9S-8752 Full Nut
36 9X-8873 Bolt
Table 8
175-3842 Water Lines Cover Gp
Quantity Part Number Part Name
2 0S-1594 Bolt
2 1A-2029 Bolt
1 1N-5998 Plug
4 3V-3308 Hard Washer
1 6L-7817 O-Ring Seal
1 6V-1585 O-Ring Seal
1 8C-0562 O-Ring Seal
2 8N-9071 Valve As
2 8S-4950 Cap
1 134-5326 Cover
1 171-5262 Cover
Table 9
166-2166 Exhaust Fitting
Quantity Part Number Part Name
8 4J-4382 Pipe Plug
32 6V-5845 Bolt
32 6V-7742 Full Nut
32 8T-3282 Hard Washer
2 166-2161 Exhaust Adapter
2 166-4572 Gasket
Table 10
154-1252 Air Cleaner Adapter
Quantity Part Number Part Name
2 4W-3637 Hose
12 6V-5049 O-Ring Seal
12 9S-4191 Plug
16 116-8535 Clamp
2 153-8355 Adapter
Table 11
Turbocharger
Quantity Part Number Part Name
2 - Napier Turbocharger Turbocharger
A Special Rating Request (SRR) is required in order to determine the part number for the turbocharger. For the 3612 Engine there are two turbochargers per engine. To enter the Special Rating Request (SRR), contact the Application Support Center (ASC) using the link below:https://eomppp.cat.com
800-448-2400