101606-0584 ZEXEL F 01G 09U 1HE BOSCH INJECTION-PUMP ASSEMBLY f01g09u1he 1016060584 1156035014

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 09U 1HE f01g09u1he

ZEXEL 101606-0584 1016060584

ISUZU 1156035014 1156035014

Service parts 101606-0584 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6851

3. GOVERNOR 105411-2721

4. SUPPLY PUMP

105220-7230

5. AUTOM. ADVANCE MECHANIS 105672-0840

6. COUPLING PLATE 105661-1170

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-8341

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 16.7(170)/19.6(200)

13. NOZZLE-HOLDER 105041-4410

14. NOZZLE

15. NOZZLE SET 105019-2900

Include in #1:

101606-0584 as INJECTION-PUMP ASSEMBLY

Include in #2:

104701-1020 as _

Cross reference number

BOSCH F 01G 09U 1HE f01g09u1he

ZEXEL 101606-0584 1016060584

ISUZU 1156035014 1156035014

Zexel num

Bosch num

Firm num

Name

101606-0584

F 01G 09U 1HE

1156035014 ISUZU

INJECTION-PUMP ASSEMBLY
6BG1-TRC-

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-5-3-6- 2-4

Pre-stroke mm 4.2 4.15 4.25

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 10.5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 102 100.5 103.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Boost pressure kPa 109 109

Boost pressure mmHg 820 820

Injection quantity adjustment_02

Adjusting point -

Rack position 7.5+-0.5

Pump speed r/min 440 440 440

Average injection quantity mm3/st. 12 10.7 13.3

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Boost compensator adjustment

Pump speed r/min 550 550 550

Rack position 9.3

Boost pressure kPa 36.7 32.7 40.7

Boost pressure mmHg 275 245 305

Boost compensator adjustment_02

Pump speed r/min 550 550 550

Rack position (10.5)

Boost pressure kPa 96 96 96

Boost pressure mmHg 720 720 720

Timer adjustment

Pump speed r/min 1300++

Advance angle deg. 0 0 0

Remarks
Do not advance until starting N = 1300.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1 1 1

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Main spring setting (5)Boost compensator stroke: BCL
----------
K=11 BCL=(1.2)mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=9deg+-5deg b=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal
----------

----------
a=53deg+-5deg b=45deg+-5deg

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2) (3)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T3)
----------
T1=2.5N-m(0.25kgf-m) T2=2.94~4.41N-m(0.3~0.45kgf-m) T3=29.4~39.2N-m(3~4kgf-m)
----------

Timing setting

(1)Pump vertical direction (2)Positions of coupling's threaded installation holes at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=6deg
----------
a=(90deg)