106673-4190 ZEXEL F 019 Z20 132 BOSCH INJECTION-PUMP ASSEMBLY f019z20132 1066734190

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 132 f019z20132

ZEXEL 106673-4190 1066734190

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Cross reference number

BOSCH F 019 Z20 132 f019z20132

ZEXEL 106673-4190 1066734190

Zexel num

Bosch num

Firm num

Name

106673-4190

F 019 Z20 132

DPICO

INJECTION-PUMP ASSEMBLY
DE08TIS Q

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600

Overflow valve 134424-4120

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.9 3.85 3.95

Beginning of injection position
Drive 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 13.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 136 134 138

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8+-0.5

Pump speed r/min 440 440 440

Average injection quantity mm3/st. 16 14.5 17.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.4)

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 136 134 138

Basic *

Fixing the lever *

Boost pressure kPa 46.7 46.7

Boost pressure mmHg 350 350

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2-1.6

Boost pressure kPa 18.7 17.4 20

Boost pressure mmHg 140 130 150

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2(R1-1. 5)

Boost pressure kPa 33.3 33.3 33.3

Boost pressure mmHg 250 250 250

Timer adjustment

Pump speed r/min 750--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 930

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL (4)Damper spring setting (5)Microswitch adjustment unnecessary.
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T1=AG99 BCL=1.6+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H' (3)Viewed from feed pump side.
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aa=70mm
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a=14deg+-5deg b=40.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)At pump speed bb and rack position cc, set the stopper bolt.
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aa=40mm bb=0r/min cc=1.5+-0.3mm
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a=44deg+-5deg b=20deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position for the No. 6 cylinder's beginning of injection (3)- (4)-
----------

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

Information:

Typical Example1. Remove bolts (1) from the alternator bracket.2. Remove the bolts that hold plate (3) and remove the plate.3. Disconnect water line (2) from the air compressor. Turn the water line tee toward the lifting bracket in order to provide clearance to remove the head bolt. 4. Remove bolts (4) and (5) that hold the cylinder head assembly to the cylinder block.5. Fasten a hoist and remove the cylinder head assembly. The weight is approximately 135 kg (300 lb).
Do not put the cylinder head assembly down on a flat surface. This can cause damage to the fuel injection valves.
6. Remove the gasket and seals from the spacer plate.Install Cylinder Head Assembly
Be sure a new gasket has been installed between the spacer plate and the cylinder block. See topic, "Remove & Install Spacer Plate". 1. Thoroughly clean the spacer plate and the bottom surface of the cylinder head assembly. Install a new head gasket, new seals (1) and two O-ring seals (2). 2. Fasten a hoist and put the cylinder head assembly (3) in position on the cylinder block.3. Tighten the bolts in sequence shown in Illustration D11970.
(1) Large bolts (3/4 inch). Put 6V4876 Molycoat Paste Lubricant on bolt threads and between washers and underside of bolt heads.(2) Small bolts (3/8 inch). See Step 4h.4. Install the cylinder head bolts and washers. Tighten the bolts in sequence shown.a. Tighten bolts 1 through 14 in number sequence to 270 25 N m (200 20 lb ft).b. Tighten bolts 1 through 14 in number sequence to 470 20 N m (345 15 lb ft).c. Tighten bolts 1 through 14 in number sequence again to 470 20 N m (345 15 lb ft).d. Install the rocker arm shafts for the engine valves and the remaining (3/4 in) bolts and/or compression brake studs.e. Tighten bolts 15 through 26 in number sequence to 270 25 N m (200 20 lb ft).f. Tighten bolts 15 through 26 in number sequence to 450 20 N m (330 15 lb ft).g. Tighten bolts 15 through 26 in number sequence again to 450 20 N m (330 15 lb ft).h. Tighten the thirteen small bolts (2) to 45 7 N m (33 5 lb ft).5. Make an adjustment to the valves to have a clearance of 0.38 mm (.015 in) for intake and 0.76 mm (.030 in) for exhaust. Tighten the locknuts for the valve adjustment screws to a torque of 28 4 N m (21 3 lb ft).6. Install the valve cover bases and the inner fuel lines. See topic, "Install Rocker Shaft Assemblies & Push Rods".7. Install the valve covers. See topic, "Install Valve Covers".
Typical Example8. Install plate (4).9. Connect the water line to the air compressor.10. Install bolts (5) for the alternator bracket.End By:a. install exhaust manifoldb. install fuel injection linesc. install aftercooler housingd. install water temperature regulatore. install rocker shaft assemblies and push rods