101607-1300 ZEXEL F 01G 09U 057 BOSCH INJECTION-PUMP ASSEMBLY f01g09u057 1016071300

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 09U 057 f01g09u057

ZEXEL 101607-1300 1016071300

Service parts 101607-1300 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9500

3. GOVERNOR 105931-7660

4. SUPPLY PUMP 105210-4641

5. AUTOM. ADVANCE MECHANIS 105643-0680

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105030-4110

14. NOZZLE

15. NOZZLE SET

Include in #1:

101607-1300 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-6608 as _

Cross reference number

BOSCH F 01G 09U 057 f01g09u057

ZEXEL 101607-1300 1016071300

Zexel num

Bosch num

Firm num

Name

101607-1300
101607-1301

F 01G 09U 057

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 131424-5520

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 3.3 3.25 3.35

Beginning of injection position
Governor 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 -

Rack position 11.2

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 57.7 56 59.4

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 275 275 275

Each cylinder's injection qty mm3/st. 13.7 11.6 15.8

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.2)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 57.7 56.7 58.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 72.6 68.6 76.6

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.8

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 59.7 55.7 63.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+1.25

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 57.1 53.1 61.1

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 130 150

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1250--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

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)RACK LIMIT
----------
T1=F21
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=10deg+-5deg b=41deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed = cc. Rack position = actual (non-injection rack position). (3)Rack position = approximately dd (4)Free (at shipping) (5)Use the hole above R = ee
----------
aa=1550r/min bb=7-0.5mm cc=275r/min dd=15mm ee=40mm
----------
a=38.5deg+-5deg b=(27deg) c=15deg+-3deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=13deg
----------
a=(0deg)