101401-9680 ZEXEL F 01G 09U 019 BOSCH INJECTION-PUMP ASSEMBLY f01g09u019 1014019680

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 09U 019 f01g09u019

ZEXEL 101401-9680 1014019680

Service parts 101401-9680 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9120

3. GOVERNOR 105921-8570

4. SUPPLY PUMP 105220-7060

5. AUTOM. ADVANCE MECHANIS 105671-0500

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6170

11. Nozzle and Holder 16600-17D02

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105048-3691

14. NOZZLE 105017-2010

15. NOZZLE SET

Include in #1:

101401-9680 as INJECTION-PUMP ASSEMBLY

106672-3811 as _

Cross reference number

BOSCH F 01G 09U 019 f01g09u019

ZEXEL 101401-9680 1014019680

Zexel num

Bosch num

Firm num

Name

101401-9680
101401-9681

F 01G 09U 019

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 6-2-600

Overflow valve 134424-4120

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

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.15 3.25

Rack position
Point A R=A

Beginning of injection position
Drive 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 14.6

Pump speed r/min 1550 1550 1550

Average injection quantity mm3/st. 108.5 106.9 110.1

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 13 11.2 14.8

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(14.6)

Pump speed r/min 1550 1550 1550

Average injection quantity mm3/st. 108.5 107.5 109.5

Basic *

Fixing the lever *

Boost pressure kPa 80 80

Boost pressure mmHg 600 600

Injection quantity adjustment_04

Adjusting point B

Rack position R1-1.05

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 88 84 92

Fixing the lever *

Boost pressure kPa 80 80

Boost pressure mmHg 600 600

Injection quantity adjustment_05

Adjusting point C

Rack position R2-0.95

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 58 54 62

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2-0.95

Boost pressure kPa 10.7 9.4 12

Boost pressure mmHg 80 70 90

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2(R1-1. 35)

Boost pressure kPa 66.7 66.7 66.7

Boost pressure mmHg 500 500 500

Timer adjustment

Pump speed r/min 1000--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 950

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1550

Advance angle deg. 5.1 4.6 5.6

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 7 6.5 7.5

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=L33 BCL=0.95+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=71deg+-5deg b=41deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg

0000001501 LEVER

(A) Speed lever (lower) (B) Stopper bolt (C) Special lever (upper) a:Point A (inside lever) 1. Special lever adjustment (1)With the speed lever at the idle position, set the accelerator lever stopper bolt so that the accelerator lever contacts the speed lever at point a. (2)Back off the stopper bolt L and set.
----------
L=1+0.5mm
----------

0000001601 POTENTIO METER

(A) : Governor plan view (B): Potentiometer harness terminal (C): Potentiometer connection diagram (D) : Output voltage standard value (S): Voltage P/M: potentiometer (v): output voltage (V) (p): direction of potentiometer rotation 1. Adjustment procedures (1)Apply DCV1 to potentiometer harness terminal (B) to obtain the specified output voltage. (2)Fix the speed lever at the full side. (3)Loosen the bolt (S), and move the potentiometer from left and right. (4)Adjust so that the output voltage at full is within the standard values. (5)Fix bolt (S). (6)Repeatedly move the speed lever from the full side to the idle side. (7)Check that it is within the standard values at full and idle.
----------
V1=5+-0.02V
----------
V1=5+-0.02V Va=(5)V Vb=4+-0.2V Vc=0.58+-0.3V

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear's distinguishing mark) at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=5deg
----------
a=(50deg)