106871-4162 ZEXEL F 019 Z20 235 BOSCH INJECTION-PUMP ASSEMBLY f019z20235 1068714162

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 235 f019z20235

ZEXEL 106871-4162 1068714162

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Service parts 106871-4162 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5930

3. GOVERNOR 105489-4810

4. SUPPLY PUMP 105237-4400

5. AUTOM. ADVANCE MECHANIS 105636-2250

6. COUPLING PLATE 105662-1360

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2)

13. NOZZLE-HOLDER

14. NOZZLE

15. NOZZLE SET

Include in #1:

106871-4162 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z20 235 f019z20235

ZEXEL 106871-4162 1068714162

Zexel num

Bosch num

Firm num

Name

106871-4162

F 019 Z20 235

DPICO

INJECTION-PUMP ASSEMBLY
EF750 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 105870-0000

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 134424-0820

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-8-6-2- 7-5-4-3

Pre-stroke mm 4.4 4.34 4.4

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point A

Rack position 9.5

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 120 117 123

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 9.6

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 121.8 119.8 123.8

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 10.4

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 145 142 148

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_04

Adjusting point D

Rack position 5.4+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11.5 8.5 14.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 160

Fixing the lever *

Remarks
After startup boost setting

Injection quantity adjustment_06

Adjusting point F

Rack position 9.4+-0.5

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 126 121 131

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Timer adjustment

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 3.5 3.2 3.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Excess fuel setting for starting: SXL (N = N1) (5)Damper spring setting
----------
RT=0.8 TH=2.6mm SXL=10.5+0.2mm N1=350r/min
----------

Speed control lever angle

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

----------
a=20deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=50mm
----------
a=39deg+-5deg b=39deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side
----------

----------
a=30deg+-5deg b=64deg+-5deg

Timing setting

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

----------
a=(80deg)

Information:

Image1.1.1
5. Attach a hose to the other end of the fuel rail and hold the free end of the hose in a cup/bucket of water. Hose shown is a JIC 37o ?6 hose. Refer to Illustration 1.2.1
Image1.2.1
6. Pressurize the cooling system with compressed air and regulate pressure between 5-15 psi.
Do Not Exceed 15 psi or Cooling System Damage Can Result.
7. Submerse the hose in a cup/bucket of water.
8. Monitor for 10 minutes and check for a steady rate of air bubbles coming out of the hose that is submersed in the cup/bucket of water.
9. If steady stream of air is present, replace the cylinder head, coolant regulators, and both 030-7937 port connectors. Depending on the application, you will need to replace some cooling system seals. (List of seals by application to be included)
10. Once the cylinder heads have been replaced pressure test the head again using the same procedure. Once this has been completed the cooling system should be flushed using instructions listed below.
Cleaning the Cooling System
1. Drain all of the coolant form cooling system.
2. Fill the cooling system with clean water.
3. Start engine and run it until the thermostat opens.
4. Add two cups of non-foaming liquid automatic dish washer soap.
Note: Do not use plain dish soap. Aeration of the cooling system and resultant damage could occur.
5. After the soap has bee added run engine for approximately twenty minutes. Check to see if the fuel is breaking up.
6. If the fuel is still not breaking up than add two more cups of soap and run for 10 minutes. Drain mixture from cooling system.
7. Fill cooling system with clean water and check surface for fuel. If fuel is present, repeat steps 3 through 7. When water is clear, drain and rinse the cooling system one more time. Then add coolant and conditioner.