106871-4271 ZEXEL F 019 Z20 244 BOSCH INJECTION-PUMP ASSEMBLY f019z20244 1068714271

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 244 f019z20244

ZEXEL 106871-4271 1068714271

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Buy INJECTION-PUMP ASSEMBLY 106871-4271 zexel genuine, new aftermarket engine parts with delivery

Service parts 106871-4271 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5860

3. GOVERNOR 105489-5140

4. SUPPLY PUMP 105237-0060

5. AUTOM. ADVANCE MECHANIS 105683-0510

6. COUPLING PLATE 105664-2190

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7850

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 14.7(150)/24.5(250)

13. NOZZLE-HOLDER 105030-3500

14. NOZZLE 105029-1290

15. NOZZLE SET

Include in #1:

106871-4271 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z20 244 f019z20244

ZEXEL 106871-4271 1068714271

Zexel num

Bosch num

Firm num

Name

106871-4271

F 019 Z20 244

DPICO

INJECTION-PUMP ASSEMBLY
F20C 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 134424-0820

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 4.5 4.44 4.5

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

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 153.5 151.5 155.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 152 149 155

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 9.2

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 151 148 154

Fixing the lever *

Injection quantity adjustment_04

Adjusting point E

Rack position 8.45

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 127.5 124.5 130.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point F

Rack position 3.9+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 12.6 9.6 15.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_06

Adjusting point G

Rack position 9.8+-0.1

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 180 176 184

Fixing the lever *

Remarks
Startup boost setting

Injection quantity adjustment_07

Adjusting point H

Rack position 10.4+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 170 170 190

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 600--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 550

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min (620--)

Advance angle deg. 1 0.7 1.3

Load 4/4

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 900+50

Advance angle deg. 1 0.7 1.3

Load 4/4

Timer adjustment_05

Pump speed r/min 1100-50

Advance angle deg. 3.25 2.95 3.55

Load 4/4

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)Set idle at point K (N = N1, R = R2) and confirm that the injection quantity does not exceed Q1 at point J (N = N2). (5)Stop lever's normal position setting: R1 (6)Excess fuel setting for starting: SXL (7)Damper spring setting
----------
RT=0.8 TH=3.5mm N1=300r/min R2=3.9mm N2=1150r/min Q1=3mm3/st R1=12+-0.1mm SXL=9.8+-0.1mm
----------

Speed control lever angle

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

----------
a=19deg+-5deg

0000000901

F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=39mm
----------
a=39deg+-5deg b=43deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (at delivery), set before governor adjustment (2)Use the pin at R = bb (3)Set the stopper bolt (apply red paint).
----------
aa=12+-0.1mm bb=37mm
----------
a=0deg+-5deg b=35deg+-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:

Image1.5.1
2. Use 4 new grommets (MCI part number 97-2246-00002 (Dealer Order)) per bus. Grommets are to be installed between the clamp and chassis frame at same location as originals.
3. Clean existing exhaust inlet pipe with wire brush for reuse. Install new Exhaust clamps (Dealer Order).
4. Clean existing exhaust Outlet pipe with wire brush for reuse. Install new Exhaust clamps (Dealer Order).
5. Use a floor jack or transmission jack with CCRT properly secured to lift into place. Place a pipe clamp loosely over the inlet socket. Use the jack to raise the CCRT assembly into position. Insert exhaust pipe elbow into inlet socket. Tighten the clamp bolt to a torque of approximately 50 lb ft. Refer image 1.5.1.
Image1.6.1
6. Provide adequate clearance to Pro Heat exhaust pipe. Mounting brackets will have 1/2 inch slotted bolt holes. Orient to provide needed clearance. Refer image 1.6.1.
Image1.7.1
7. Install Thermocouple.
- Apply a thin coat of anti-seize to the threads of the Male Run Tee and thread it into the boss on the CCRT inlet. Image 1.7.1 shows a completed installation.
- All the parts used from Step 7 to Step 10 are included in the 219-7990 Installation Kit.
Image1.8.1
8. Insert the reducer fitting into the Tee fitting in line with the boss (Image 1.8.1). Tighten the lock nut (also use the Lock Washer) on the Tee until it is finger tight and then tighten it 1 1/4 turns with a 9/16" wrench.
Image1.9.1
9. Insert the thermocouple into the reducer as far as it will go, then pull it back 1/4 inch (Image 1.9.1). Tighten the lock nut finger tight and then tighten 1 1/4 turns with a 7/16" wrench. If necessary, the thermocouple may be bent ONCE to avoid any interference. Do not bend the thermocouple past 90 degrees.
NOTE. JM instructions instruct to insert probe and withdraw one inch. For this installation, insert probe and withdraw 1/4 inch to allow accurate temperature measurement of the exhaust.
Image1.10.1
10. Insert the copper tubing into the fitting on the Tee that is at a 90 degree angle to the boss (Image 1.10.1). Tighten the fitting on the Tee until it is finger tight. Then tighten it 1 1/4 turns with a 9/16" wrench.
Image1.11.1
Image1.11.2
11. Route the cable and copper tube and the secure cable with 6K0806 Cable Straps as shown. It is important to use these cable straps so the tube and cable are oriented in a way that they do not rub against the frame.
Install P brackets every two to three feet as needed. Refer in Image 1.11.2.
12. Install 271-6537 CCRT Diagnostic Module using Bolts (4M5282), Washers (8T4205), nut (6V8185) and Lock Washer (3B4504). Use carbide tip drill bit for drilling in stainless steel.
Image1.13.1
13. Install 282-0031 Remote Display monitor lights along with dealer fabricated Remote Display Bracket. Use self tapping screws (90064A581), Splice (1364877), Washer (4B4274), Locknut (031049) and screw (4B1232).
Image1.14.1
14. Connect power using 3A Fuse.
15. Install existing Pin insulator on the weatherpack plug that connects to the OEM harness at the firewall that provides power to the CRT module.
16. Download