106671-9901 ZEXEL F 019 Z20 102 BOSCH INJECTION-PUMP ASSEMBLY f019z20102 1066719901

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 102 f019z20102

ZEXEL 106671-9901 1066719901

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Cross reference number

BOSCH F 019 Z20 102 f019z20102

ZEXEL 106671-9901 1066719901

Zexel num

Bosch num

Firm num

Name

106671-9901

F 019 Z20 102

DPICO

INJECTION-PUMP ASSEMBLY
Q-DD 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 11.7

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 142 138.4 145.6

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position R3(6)

Pump speed r/min 300 300 300

Each cylinder's injection qty mm3/st. 16 13.7 18.3

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.7)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 142 141 143

Basic *

Fixing the lever *

Boost pressure kPa 72 72

Boost pressure mmHg 540 540

Injection quantity adjustment_04

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 80 40 120

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 R2-2

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R2(R1(11 .7))

Boost pressure kPa 58.7 58.7 58.7

Boost pressure mmHg 440 440 440

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+-0.1mm DL=(R3-0.2)-0.2mm N1=1100r/min N2=700r/min
----------

Speed control lever angle

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

----------
a=(15.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=46mm
----------
a=18deg+-5deg b=(31.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting
----------
aa=(3.5)-0.5mm
----------
a=38deg+-5deg b=(38deg)+7deg-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:

Table 1
Revision Summary of Changes
01 Added serial number prefixes Description Of Change: The improved Diesel Exhaust Fluid (DEF) filters have updated material to reduce debris passing to the DEF pump.Adaptable To:
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.
The following changes are adaptable to the products within the listed serial numbers, and are effective with all products after the listed serial numbers.The new and former DEF filter part numbers are listed in Table 2.
Table 2
Required Parts
Qty New Part Number Part Name Former Part Numbers(1)
1 584-8135 Diesel Exhaust Fluid Filter Gp 453-1604
1 584-8136 Diesel Exhaust Fluid Filter Gp 453-1605
1 584-8137 Diesel Exhaust Fluid Filter Gp 453-1606
(1) The former part number listed is for reference only and may differ.