106671-9571 ZEXEL F 019 Z20 089 BOSCH INJECTION-PUMP ASSEMBLY f019z20089 1066719571

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 089 f019z20089

ZEXEL 106671-9571 1066719571

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Cross reference number

BOSCH F 019 Z20 089 f019z20089

ZEXEL 106671-9571 1066719571

Zexel num

Bosch num

Firm num

Name

106671-9571

F 019 Z20 089

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 12.3

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 154 150.1 157.9

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position R2(5.5)

Pump speed r/min 325 325 325

Each cylinder's injection qty mm3/st. 11 9.4 12.6

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 154 153 155

Basic *

Fixing the lever *

Boost pressure kPa 84 84

Boost pressure mmHg 630 630

Injection quantity adjustment_04

Adjusting point G

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 90 130

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position (R3-2.5)

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position R3-0.8

Boost pressure kPa 45.3 44.6 46

Boost pressure mmHg 340 335 345

Boost compensator adjustment_03

Pump speed r/min 550 550 550

Rack position R3(R1(12 .3))

Boost pressure kPa 70.6 67.3 73.9

Boost pressure mmHg 530 505 555

Timer adjustment

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 0/4

Remarks
Measure speed (beginning of operation).

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 0 0 0

Load 0/4

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 0 0 0

Load 4/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 3.5 2.8 4

Load 4/4

Remarks
Measure the actual speed, stop

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: DL (4)Rack difference between N = N1 and N = N2
----------
BCL=(2.5)+-0.1mm DL=(R2-0.2)-0.2mm N1=1000r/min N2=700r/min
----------

Speed control lever angle

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

----------
a=(17.5deg)+-5deg

0000000901

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

----------
a=21deg+-5deg b=33deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = actual measurement (2)Stopper bolt setting (3)(Actual measurement)
----------

----------
a=38deg+-5deg

Timing setting

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

----------
a=(6deg)

Information:

Introduction
The problem that is identified below has a known solution. Use the solution that is identified below.Problem
The procedure for the Disassembly and Assembly needs to be updated to include the information below.Solution
Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.
Inspect the quill tubes and fuel injectors for cuts or marks at the mating surfaces.
Replace any quill tubes since the quill tubes are a one time use component. Replace the copper washer when replacing the fuel injector.
Follow the steps below for installing the quill tunes and fuel injectors.
Seat the injector by installing and torquing the injector hold down clamp bolt to 30 3 N m (22 2 lb ft).
Install the quill tube and tighten the quill nut between 15 N m (11 lb ft) to 20 N m (15 lb ft).
Apply a final torque of 30 3 N m (22 2 lb ft) to the injector hold down clamp bolt.
Apply a final torque between 50 N m (37 lb ft) to 55 N m (41 lb ft).