106871-9250 ZEXEL F 019 Z20 272 BOSCH INJECTION-PUMP ASSEMBLY f019z20272 1068719250

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 272 f019z20272

ZEXEL 106871-9250 1068719250

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Cross reference number

BOSCH F 019 Z20 272 f019z20272

ZEXEL 106871-9250 1068719250

Zexel num

Bosch num

Firm num

Name

106871-9250

F 019 Z20 272

DPICO

INJECTION-PUMP ASSEMBLY
8DC9 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 134424-1320

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

Pre-stroke mm 4.8 4.75 4.85

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point -

Rack position 9

Pump speed r/min 700 700 700

Each cylinder's injection qty mm3/st. 98.5 95.5 101.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point F

Rack position 5.8+-0.5

Pump speed r/min 450 450 450

Each cylinder's injection qty mm3/st. 17.5 15.7 19.3

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(9)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 98.5 97.5 99.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point C

Rack position 6.3+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 20 14 26

Fixing the rack *

Remarks
(check)

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 130 90 170

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min (N1+50)- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min N1(800)

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min (1020)

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (3)Damper spring setting
----------
SXL=9.4+-0.1mm
----------

Speed control lever angle

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

----------
a=19.5deg+-5deg

0000000901

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

----------
a=10deg+-5deg b=23.5deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Rack position bb (4)Free (at delivery) (5)Drive side (6)R = cc
----------
aa=4-0.5mm bb=(13.2)mm cc=36mm
----------
a=45.5deg+7deg-5deg b=22deg+-5deg c=(10.5deg)

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=325r/min Ra=5.8+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(40deg)

Information:

(1) Crossbar (from 8B7548 Puller).(2) Spacer plate.(3) S1589 Bolt with two 1S379 Washers.(4) 1D4595 Bolt.(5) 3H465 Plate.(6) 1P2403 Dial Indicator.(7) 1P2394 Adapter Plate.(8) 1P2402 Gauge Body.Make reference to Cylinder Liner Projection in Testing and Adjusting for the complete procedure.1. Install gasket and spacer plate (2) with bolts (3) and two 1S379 Washers. Tighten bolts (3) evenly in four steps: 1st step ... 14 N m (10 lb ft)2nd step ... 35 N m (25 lb ft)3rd step ... 70 N m (50 lb ft)4th step ... 95 N m (70 lb ft)2. Install tools as shown. Tighten bolts (4) evenly in four steps: 1st step ... 7 N m (5 lb ft)2nd step ... 20 N m (15 lb ft)3rd step ... 35 N m (25 lb ft)4th step ... 70 N m (50 lb ft)3. Measure cylinder liner projection with dial indicator (6) in 1P2402 Gauge Body (8) as shown. Measure at four places around each cylinder liner near the clamped area. Cylinder liner projection measurements for any cylinder liner must be ... 0.033 to 0.175 mm (.0013 to .0069 in)Maximum permissible difference between all four measurements ... 0.05 mm (.002 in)Maximum permissible difference between average projection of any two cylinder liners next to each other ... 0.05 mm (.002 in)Maximum permissible difference between average projection of all cylinder liners under one cylinder head ... 0.10 mm (.004 in) If liner projection is not correct, turn the liner to a new position within the bore. If projection can not be corrected this way, move the liner to a different bore. If the projection can not be corrected this way, make reference to Special Instruction, Form No. FMO55228 for complete instructions on the use of 8S3140 Counterboring Tool Arrangement. 4. Minimum permissible depth to machine counterbore to adjust cylinder liner projection ... 0.76 mm (.030 in) Maximum permissible depth to machine counterbore to adjust cylinder liner projection ... 1.14 mm (.045 in)Install a 0.76 mm (.030 in) shim plus any added shims necessary to get the correct cylinder liner projection. Be sure that the 0.76 mm (.030 in) shim is directly under the cylinder liner flange.