101401-7274 ZEXEL F 01G 09U 00P BOSCH INJECTION-PUMP ASSEMBLY f01g09u00p 1014017274

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 09U 00P f01g09u00p

ZEXEL 101401-7274 1014017274

Service parts 101401-7274 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-8531

3. GOVERNOR 105932-1801

4. SUPPLY PUMP 105210-6170

5. AUTOM. ADVANCE MECHANIS 105676-8040

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-7232

11. Nozzle and Holder 8-97115-503-1

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

13. NOZZLE-HOLDER 105048-3831

14. NOZZLE

15. NOZZLE SET 105019-1070

Include in #1:

101401-7274 as INJECTION-PUMP ASSEMBLY

101601-5890 as _

101602-2660

Cross reference number

BOSCH F 01G 09U 00P f01g09u00p

ZEXEL 101401-7274 1014017274

Zexel num

Bosch num

Firm num

Name

101401-7274
101401-7275

F 01G 09U 00P

INJECTION-PUMP ASSEMBLY
* K 14BD PE4AD PE

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 134424-3920

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 3.8 3.75 3.85

Rack position
Point A R=A

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 13.1

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 97 95.4 98.6

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.8+-0.5

Pump speed r/min 290 290 290

Average injection quantity mm3/st. 14.5 13.2 15.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.1)

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 97 96 98

Basic *

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.35

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 96.5 92.5 100.5

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_05

Adjusting point C

Rack position R2-0.45

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 86 82 90

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 95 95 127

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R2-0.45

Boost pressure kPa 27.3 26 28.6

Boost pressure mmHg 205 195 215

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R2(R1-0. 6)

Boost pressure kPa 46.7 46.7 46.7

Boost pressure mmHg 350 350 350

Timer adjustment

Pump speed r/min 1185--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1135

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1450

Advance angle deg. 4.8 4.3 5.3

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 5 4.5 5.5

Remarks
Measure the actual speed, stop

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=N23 BCL=0.45+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (rack position = aa, speed = bb)
----------
aa=(9.7)mm bb=310r/min
----------
a=40deg+-5deg b=30deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg

0000001501 FICD

(A) applied negative pressure (B) Screw (c) Nut 1. Set the actuator as described below. (1)Confirm that there is clearance between the actuator lever and the speed lever. (2)Loosen the nut (C). (3)Push in the screw (B). (4)Apply P1 from the actuator (A) part. (5)Pull out the screw (B) slowly. (6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra. (7)Torque the nut (C) to T1. (8)Apply P2 several times. (9)Confirm that the actuator functions normally. (10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=425r/min Ra=9.1+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Stamping position on the A/T outer rim (4)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1. (5)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)