107691-2140 ZEXEL F 019 Z20 427 BOSCH INJECTION-PUMP ASSEMBLY f019z20427 1076912140

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 019 Z20 427 f019z20427

ZEXEL 107691-2140 1076912140

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Buy INJECTION-PUMP ASSEMBLY 107691-2140 zexel genuine, new aftermarket engine parts with delivery

Service parts 107691-2140 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-1180

3. GOVERNOR 105921-7240

4. SUPPLY PUMP

5. AUTOM. ADVANCE MECHANIS 105681-1090

6. COUPLING PLATE 105663-0760

7. COUPLING PLATE

8. _ 159590-3421

9. _

10. NOZZLE AND HOLDER ASSY 105118-5381

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105048-3730

14. NOZZLE 105017-1221

15. NOZZLE SET

Include in #1:

107691-2140 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 019 Z20 427 f019z20427

ZEXEL 107691-2140 1076912140

Zexel num

Bosch num

Firm num

Name

107691-2140
107691-2141

F 019 Z20 427

INJECTION-PUMP ASSEMBLY
* K 14CG TICS MD-TI6 TICS

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 131425-0520

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 157 157 157

Tester oil delivery pressure kgf/cm2 1.6 1.6 1.6

PS/ACT control unit part no. 407910-3 03*

Selector switch no. 01

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 15

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 5.6 5.57 5.63

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.75 60.25

Difference between angles 2
Cal 1-3 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cyl.1-2 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-4 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 10.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 77 75.4 78.6

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 7.5+-0.5

Pump speed r/min 670 670 670

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.8)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 77 76 78

Basic *

Fixing the lever *

Boost pressure kPa 48 48

Boost pressure mmHg 360 360

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.45

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 91.4 87.4 95.4

Fixing the lever *

Boost pressure kPa 48 48

Boost pressure mmHg 360 360

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_05

Adjusting point C

Rack position R3(R1-0. 9)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 37.1 33.1 41.1

Fixing the lever *

Boost pressure kPa 48 48

Boost pressure mmHg 360 360

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_06

Adjusting point D

Rack position R3-0.9

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 21 17 25

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R3-0.9

Boost pressure kPa 15.3 14 16.6

Boost pressure mmHg 115 105 125

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R3(R1-0. 9)

Boost pressure kPa 34.7 34.7 34.7

Boost pressure mmHg 260 260 260

Timer adjustment

Pump speed r/min 1070--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1020

Advance angle deg. 0 -0.5 0

Timer adjustment_03

Pump speed r/min 1080

Advance angle deg. -1.3 -1.8 -0.8

Remarks
Finish

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

_03

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

_04

CU407910-303* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_05

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

_06

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

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
----------
T1=G34 BCL=0.9+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=24deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position) and confirm non-injection.
----------
aa=1670r/min bb=4.5-0.5mm
----------
a=15deg+-5deg b=38deg+-5deg

0000001301

(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)Pre-stroke: bb
----------
aa=6deg bb=5.6+-0.03mm
----------
a=(7deg)

0000001401

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------

----------

0000001701

A : Stopper pin B: Connector
----------

----------

0000001801

C:Shim
----------

----------

0000001901

A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------

----------

0000002201 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1500r/min Ra=R1(10.8)+1.45mm
----------

0000002301 SPEED SENSOR

(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------

Information:

Illustration 4 g01784824
Right side view of machine (A) Hood and guard group (B) Lines group (Air) (C) Air cleaner
Illustration 5 g01784914
Front view of machineInstallation Procedure
The installation procedure that follows is specific for the listed machine.Diesel Particulate Filter Installation
Illustration 6 g01784177
(2) 331-8935 Bracket (12) 5P-8245 Hard Washer (13) 6V-8149 Nut (14) 8F-6437 Washer (15) 8T-4956 Bolt
Place two new 331-8935 Brackets (2) parallel to each other on top of the hood. Secure the brackets by using four new 8F-6437 Washers (14), four new 5P-8245 Hard Washers (12), four new 6V-8149 Nuts (13) and four new 8T-4956 Bolts (15). Refer to Illustration 6.
Illustration 7 g01784193
(5) 295-3044 Exhaust Support Gp (Lower half) (14) 8F-6437 Washer (15) 8T-4956 Bolt
Install the two lower halves of the new 295-3044 Exhaust Support Gp (5) onto two brackets (2) using four new 8F-6437 Washers (14) and four new 8T-4956 Bolts (15). Refer to Illustration 7.
Illustration 8 g01784213
(1) 331-8928 Diesel Particulate Filter Gp (5a) Clamp As (Upper half) (5b) Bolts (5c) Hard Washers (5d) Weld Nuts
Place 331-8928 Diesel Particulate Filter Gp (1) onto the two lower halves of exhaust support group (5). The weight of the diesel particulate filter group is approximately 43.6 kg (96.1 lb). Refer to Illustration 8.
Install the two upper clamp assemblies (5a) onto the two lower halves of exhaust support group (5) by using four hard washers (5c), four weld nuts (5d) and four bolts (5b). Refer to Illustration 8.
Illustration 9 g01784214
(9) 174-5414 Clamp (11) 255-2899 Tail Pipe As
Install the new 255-2899 Tail Pipe As (11) to the outlet module tube of the diesel particulate filter group. Refer to Illustration 9.
Secure tail pipe assembly (11) to the outlet module tube of diesel particulate filter group by using a new 174-5414 Clamp (9). Refer to Illustration 9.
Illustration 10 g01784215
(3) 331-9047 Filter Tube As (7) 241-6170 Plug (8) 8T-6765 Pipe Plug (10) 209-4589 Clamp
Install the new 331-9047 Filter Tube As (3) to the inlet module tube of the diesel particulate filter group. Refer to Illustration 10.
Secure filter tube assembly (3) to the inlet module tube of the diesel particulate filter group by using one new 209-4589 Clamp (10). Refer to Illustration 10.
Install the new 241-6170 Plug (7) and 8T-6765 Pipe Plug (8) onto the bosses that are provided on filter tube assembly (3). Refer to Illustration 10.
Illustration 11 g01784216
(6) 270-0112 Bellows (10) 209-4589 Clamp
Install the new 270-0112 Bellows (6) to filter tube assembly (3). Refer to Illustration 11.
Secure bellows (6) to filter tube assembly (3) by using one new 209-4589 Clamp (10). Refer to Illustration 11.
Illustration 12 g01784217
(4) 331-8934 Filter Tube (10) 209-4589 Clamp
Install the new 331-8934 Filter Tube (4) into bellows (6). Refer to Illustration 12.
Secure filter tube (4) to bellows (6) by using one new 209-4589 Clamp (10). Refer to Illustration 12.
Connect