101491-9991 ZEXEL F 01G 09U 02A BOSCH INJECTION-PUMP ASSEMBLY f01g09u02a 1014919991

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 09U 02A f01g09u02a

ZEXEL 101491-9991 1014919991

Service parts 101491-9991 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9870

3. GOVERNOR 105921-6240

4. SUPPLY PUMP 105220-6020

5. AUTOM. ADVANCE MECHANIS 105671-0220

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-5501

11. Nozzle and Holder 16600-0T003

12. Open Pre:MPa(Kqf/cm2) 18.6{190}

13. NOZZLE-HOLDER 105048-3760

14. NOZZLE

105017-1320

15. NOZZLE SET

Include in #1:

101491-9991 as INJECTION-PUMP ASSEMBLY

106672-9682 as _

106672-9683

Cross reference number

BOSCH F 01G 09U 02A f01g09u02a

ZEXEL 101491-9991 1014919991

Zexel num

Bosch num

Firm num

Name

101491-9991
101491-9992

F 01G 09U 02A

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 131424-1520

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 1-3-4-2

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 12.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 73.1 71.5 74.7

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 9 7.2 10.8

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 73.1 72.1 74.1

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 79.9 75.9 83.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 109 93 125

Fixing the lever *

Timer adjustment

Pump speed r/min 1010--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 960

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min (1030)

Advance angle deg. 0.8 0.5 1.1

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 0.8 0.5 1.1

Remarks
Measure the actual speed.

Timer adjustment_05

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

Remarks
Finish

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.
----------
T1=H20
----------

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=70deg+-5deg b=(40deg)+-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
----------

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear mark 'S') at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(60deg)