106873-2162 ZEXEL F 019 Z10 013 BOSCH INJECTION-PUMP ASSEMBLY f019z10013 1068732162

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z10 013 f019z10013

ZEXEL 106873-2162 1068732162

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Buy INJECTION-PUMP ASSEMBLY 106873-2162 zexel genuine, new aftermarket engine parts with delivery

Service parts 106873-2162 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7800

3. GOVERNOR 105489-2250

4. SUPPLY PUMP 105207-1140

5. AUTOM. ADVANCE MECHANIS 105681-0921

6. COUPLING PLATE 105663-0390

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7972

11. Nozzle and Holder ME091276

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-5000

14. NOZZLE

105015-9440

15. NOZZLE SET

Include in #1:

106873-2162 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z10 013 f019z10013

ZEXEL 106873-2162 1068732162

Zexel num

Bosch num

Firm num

Name

106873-2162
106873-2163

F 019 Z10 013

INJECTION-PUMP ASSEMBLY
* K

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 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 10.7

Pump speed r/min 650 650 650

Each cylinder's injection qty mm3/st. 133.5 129.5 137.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.2+-0.5

Pump speed r/min 225 225 225

Each cylinder's injection qty mm3/st. 17.5 14.9 20.1

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.7)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 133.5 132.5 134.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 141.6 137.6 145.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point E

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 100 180

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Adjust with speed control lever at full position (minimum-maximum speed specification) (2)Adjust with the load control lever in the full position (variable speed specification). (3)Lever ratio: RT (4)Target shim dimension: TH (5)Tolerance for racks not indicated: +-0.05mm. (6)Excess fuel setting for starting: SXL (7)Damper spring setting (8)When air cylinder is operating.
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RT=1 TH=2.7mm SXL=13.8+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)- (2)Air cylinder's adjustable range (3)Pump speed = aa (4)Pump speed = bb (5)Pump speed cc
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aa=1160r/min bb=275r/min cc=710r/min
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a=(11.5deg) b=(11.5deg)+-5deg c=(19.5deg)+-5deg d=4deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
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a=10deg+-5deg b=28deg+-3deg

Stop lever angle

S:Stop the pump. (1)Rack position = aa (2)Stopper bolt setting (3)Free (at shipping)
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aa=4.1-0.5mm
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a=10.5deg+-5deg b=55.5deg+7deg-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
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N1=325r/min Ra=5.7+-0.1mm
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0000001601 2-STAGE CHANGEOVER DEVICE

RFD governor 2 stage changeover mechanism adjustment outline (A) Bolt (B) bolt (c) Nut (D) Return spring (E) Bolt (F) Bolt (G) Screw (H) Bolt (I) Load lever (J) Speed lever (K) Air cylinder (M Air inlet Figure 1 is only for reference. Lever shape, etc, may vary. 1. Minimum-maximum speed specification adjustment (when running) (a) Without applying air to the air cylinder, loosen bolts (A) and (B). (1)High speed return L setting (a) In the speed range Nf~Nf - 300r/min, adjust using the speed adjusting bolt to determine the temporary beginning of high speed control speed. (b) Determine the rack position in the vicinity of Rf using the full load lever. (c) Increase speed and confirm return distance L. (d) Adjust using the tension lever bolt to obtain L. (2)Setting full load rack position Rf (a) Move the load control lever to the full side. (b) Adjust the full load adjusting bolt so that Rf can be obtained, then fix. (3)Setting the beginning of high speed operation Nf (a) Adjust using bolt (E) so that Nf can be obtained, and then fix. (4)Idle control setting (Re, Ni, Rc) (a) Set the speed at Ns + 200r/min and move the load control lever to the idle side. (b) Fix the lever in the position where Re can be obtained. (c) Next, decrease speed to Ni and screw in the idle spring. (d) Adjust to obtain rack position Ri. (e) Increase the speed and after confirming that the rack position is Re at Ns, set the speed at 0. (f) Confirm protrusion position Rc at idle. (5)Damper spring adjustment (a) Increase speed and set the speed at the rack position Rd - 0.1 mm (b) Set using the damper spring so that the rack position Rd can be obtained. (c) When Rd is not specified, Rd = Ri - 0.5 mm. (6)High speed droop confirmation (a) Return the load control lever to the full load lever position. (b) Increase the speed and confirm that Rf can be obtained at Nf r/min. (c) Confirm that speed is Nh at rack position Rh. 2. Variable speed specification adjustment (at operation) (a) Remove return spring (D). (b) Apply air pressure of 245~294 kPa {2.5~3 kg/cm2} to the air cylinder. (c) Perform the following adjustment in this condition. (1)Setting full load rack position Rf' (a) Pull the load lever to the idle side. (b) Obtain rack position Rf' using the nut (C). (Pump speed is Nf'-50 r/min.) (2)Setting full speed Nf' (a) Adjust using bolt (B) so that Nf can be obtained, and then fix. (3)Low speed side setting (a) At 350r/min, set bolt (F) at beginning of governor operation position, then fix. 3. Bolt (A) adjustment (1)Install return spring (D) and perform the adjustments below at air pressure 0. (a) Set at speed Nf using bolt (E). (b) Screw in bolt (A). (c) Screw in 1 more turn from the speed lever contact position (d) Fix bolt (A). (e) At this time confirm that the air cylinder's shaft moves approximately 1 mm towards the governor. 4. Lever operation confirmation using the air cylinder (1)Apply 588 kPa {6 kg/cm2} air pressure to the air cylinder. (2)Confirm that the cylinder piston is moved 50 mm by the spring (D).
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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=12deg
----------
a=(40deg)

Information:

Start By:a. remove governor **See Disassemble Governor story
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Remove the bolts and the plate from the side of the fuel injection pump housing. 2. Install tool (A) in the fuel injection pump housing. Move the rack until tool (A) can be installed to hold the rack in the center position to remove the fuel injection pumps.3. Use tool (B) to remove bushing (1).4. Remove the O-ring seal from the fuel injection pump housing. 5. Install tool (C) on the bonnet and remove the fuel injection pump. 6. Remove spacer (2). Keep the spacers (2) from the fuel injection pumps together with identification as to their location in the pump housing.7. Perform steps 3 through 6 to remove the other fuel injection pumps. The following steps are to install the fuel injection pumps.8. Install spacer (2).9. Install tool (A). Move the rack until tool (A) can be installed to hold the rack in the center position. The rack must be in the center position to install the fuel injection pumps.10. Turn camshaft until the lobe of the camshaft is down for the pump to be installed.11. Install tool (C) on the bonnet on the fuel injection pump.12. Install the fuel injection pump in the pump housing with saw cut slot in the gear in alignment with the small pin and groove in the barrel in alignment with dowel in the pump housing.13. Put clean oil on O-ring seal and install it in the fuel injection pump housing.14. Install the bushing by hand until the bushing is even with the top of the housing. If the bushing can not be installed this far by hand, remove it. Remove the fuel injection pump ad put the pump in alignment again and install the bushing again.15. Install tool (B) on the bushing and tighten the bushing to a torque of 190 14 N m (140 10 lb ft).16. Install tooling (D) to measure total rack travel. Correct rack travel is 15.7 mm (.618 in). A smaller measurement is an indication of improper fuel injection pump installation.17. Perform Steps 1 through 9 to install the other fuel pumps18. Install the cover and gasket on the fuel injection pump housing.End By:a. install governor **See Assemble Governor storyDisassemble And Assemble Fuel Injection Pumps
Start By:a. remove fuel injection pumps
When the injection pumps are disassembled, handle the parts carefully. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not intermix the plunger of one pump in the barrel with another pump. If one part is worn, install a complete new pump assembly. Be careful when placing the plunger into the bore of the barrel.
1. Pull plunger (1) and washer (5) out of barrel (3) and spring (2).
Do not remove the gear from