101403-9041 ZEXEL F 01G 09U 01F BOSCH INJECTION-PUMP ASSEMBLY f01g09u01f 1014039041

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 09U 01F f01g09u01f

ZEXEL 101403-9041 1014039041

Service parts 101403-9041 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9430

3. GOVERNOR 105921-9851

4. SUPPLY PUMP 105220-7060

5. AUTOM. ADVANCE MECHANIS 105671-0610

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6620

11. Nozzle and Holder 16600-19D20

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

13. NOZZLE-HOLDER 105048-4270

14. NOZZLE 105017-2440

15. NOZZLE SET

Include in #1:

101403-9041 as INJECTION-PUMP ASSEMBLY

101605-9400 as _

Cross reference number

BOSCH F 01G 09U 01F f01g09u01f

ZEXEL 101403-9041 1014039041

Zexel num

Bosch num

Firm num

Name

101403-9041
101403-9042

F 01G 09U 01F

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 14.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 98.5 96.9 100.1

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. 10 8.2 11.8

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(14.1)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 98.5 97.5 99.5

Basic *

Fixing the lever *

Boost pressure kPa 60.7 60.7

Boost pressure mmHg 455 455

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 112 108 116

Fixing the lever *

Boost pressure kPa 60.7 60.7

Boost pressure mmHg 455 455

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R2-1.65

Boost pressure kPa 14 12.7 15.3

Boost pressure mmHg 105 95 115

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R2(R1-0. 15)

Boost pressure kPa 47.3 47.3 47.3

Boost pressure mmHg 355 355 355

Timer adjustment

Pump speed r/min 780--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 730

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1550

Advance angle deg. 5.7 5.2 6.2

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=N79 BCL=1.65+-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=15mm
----------
a=10deg+-5deg b=29deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=8deg
----------
a=(50deg)