104761-2002 ZEXEL F 01G 09W 00T BOSCH INJECTION-PUMP ASSEMBLY f01g09w00t 1047612002


104761-2002 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH F 01G 09W 00T f01g09w00t
ZEXEL 104761-2002 1047612002

Cross reference number

BOSCH F 01G 09W 00T f01g09w00t
ZEXEL 104761-2002 1047612002


Zexel num
Bosch num
Firm num
Name
104761-2002 
104761-2003 
F 01G 09W 00T 
   
INJECTION-PUMP ASSEMBLY
* K

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113orSAEJ967d
Test oil temperature degC   45 45 50
Nozzle   105780-0060
Bosch type code   NP-DN0SD1510
Nozzle holder   105780-2150
Opening pressure MPa   13 13 13.3
Opening pressure kgf/cm2   133 133 136
Injection pipe   157805-7320
Injection pipe
Inside diameter - outside diameter - length (mm)
mm   2-6-450
Joint assembly   157641-4720
Tube assembly   157641-4020
Transfer pump pressure kPa   20 20 20
Transfer pump pressure kgf/cm2   0.2 0.2 0.2
Direction of rotation (viewed from drive side)
Right
  R
(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF.
  OFF
Injection timing adjustment
Pump speed r/min   600 600 600
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   31.1 30.6 31.6
Difference in delivery mm3/st.   2.5
Basic   *
Oil temperature degC   50 48 52
Remarks
NA
 
Injection timing adjustment_02
Pump speed r/min   600 600 600
Boost pressure kPa   16 14.7 17.3
Boost pressure mmHg   120 110 130
Average injection quantity mm3/st.   34.2 33.7 34.7
Difference in delivery mm3/st.   2.5
Basic   *
Oil temperature degC   50 48 52
Remarks
CBS
 
Injection timing adjustment_03
Pump speed r/min   500 500 500
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   31.1 29.1 33.1
Oil temperature degC   48 46 50
Injection timing adjustment_04
Pump speed r/min   600 600 600
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   31.1 30.1 32.1
Difference in delivery mm3/st.   2.5
Basic   *
Oil temperature degC   50 48 52
Injection timing adjustment_05
Pump speed r/min   600 600 600
Boost pressure kPa   8.7 7.4 10
Boost pressure mmHg   65 55 75
Average injection quantity mm3/st.   31.1 30.1 32.1
Oil temperature degC   50 48 52
Injection timing adjustment_06
Pump speed r/min   600 600 600
Boost pressure kPa   16 14.7 17.3
Boost pressure mmHg   120 110 130
Average injection quantity mm3/st.   34.2 33.2 35.2
Difference in delivery mm3/st.   2.5
Basic   *
Oil temperature degC   50 48 52
Injection timing adjustment_07
Pump speed r/min   1200 1200 1200
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Average injection quantity mm3/st.   45.2 42.7 47.7
Oil temperature degC   50 48 52
Injection timing adjustment_08
Pump speed r/min   1800 1800 1800
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Average injection quantity mm3/st.   45 42 48
Oil temperature degC   50 48 52
Injection timing adjustment_09
Pump speed r/min   2200 2200 2200
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Average injection quantity mm3/st.   43.6 40.6 46.6
Oil temperature degC   52 50 54
Injection timing adjustment_10
Pump speed r/min   2300 2300 2300
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Average injection quantity mm3/st.   43.7 40.2 47.2
Oil temperature degC   52 50 54
Injection quantity adjustment
Pump speed r/min   2500 2500 2500
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Average injection quantity mm3/st.   20.5 19.5 21.5
Difference in delivery mm3/st.   4.5
Basic   *
Oil temperature degC   55 52 58
Injection quantity adjustment_02
Pump speed r/min   2500 2500 2500
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Average injection quantity mm3/st.   20.5 19 22
Difference in delivery mm3/st.   5
Basic   *
Oil temperature degC   55 52 58
Injection quantity adjustment_03
Pump speed r/min   2800 2800 2800
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Average injection quantity mm3/st.   4.5
Oil temperature degC   55 52 58
Governor adjustment
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   10 9 11
Difference in delivery mm3/st.   1.3
Basic   *
Oil temperature degC   48 46 50
Governor adjustment_02
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   10 8 12
Difference in delivery mm3/st.   1.8
Basic   *
Oil temperature degC   48 46 50
Governor adjustment_03
Pump speed r/min   800 800 800
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   5
Oil temperature degC   50 48 52
Boost compensator adjustment
Pump speed r/min   900 900 900
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   16.5 10 23
Oil temperature degC   50 48 52
Lever angle (shim thickness) mm   8.7 8.65 8.75
Boost compensator adjustment_02
Pump speed r/min   1200 1200 1200
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   11.3 4.3 18.3
Oil temperature degC   50 48 52
Lever angle (shim thickness) mm   8.7 8.65 8.75
Timer adjustment
Pump speed r/min   100 100 100
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   40 40
Basic   *
Oil temperature degC   48 46 50
Timer adjustment_02
Pump speed r/min   100 100 100
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   40 40
Oil temperature degC   48 46 50
Speed control lever angle
Pump speed r/min   375 375 375
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   4
Oil temperature degC   48 46 50
Remarks
Magnet OFF at idling position
 
Speed control lever angle_02
Pump speed r/min   600 600 600
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Average injection quantity mm3/st.   0 0 0
Oil temperature degC   50 48 52
Remarks
Magnet OFF at full-load position
 
0000000901
Pump speed r/min   900 900 900
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Overflow quantity with S/T OFF cm3/min   560 430 690
Oil temperature degC   50 48 52
Remarks
With an O-ring
 
Stop lever angle
Pump speed r/min   900 900 900
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Pressure with S/T ON kPa   382 343 421
Pressure with S/T ON kgf/cm2   3.9 3.5 4.3
Pressure with S/T OFF kPa   431 402 460
Pressure with S/T OFF kgf/cm2   4.4 4.1 4.7
Basic   *
Oil temperature degC   50 48 52
Remarks
OFF
 
Stop lever angle_02
Pump speed r/min   900 900 900
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Pressure with S/T ON kPa   353 304 402
Pressure with S/T ON kgf/cm2   3.6 3.1 4.1
Pressure with S/T OFF kPa   431 392 470
Pressure with S/T OFF kgf/cm2   4.4 4 4.8
Basic   *
Oil temperature degC   50 48 52
Stop lever angle_03
Pump speed r/min   1200 1200 1200
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Pressure with S/T OFF kPa   490 451 529
Pressure with S/T OFF kgf/cm2   5 4.6 5.4
Oil temperature degC   50 48 52
Stop lever angle_04
Pump speed r/min   2300 2300 2300
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Pressure with S/T OFF kPa   765 726 804
Pressure with S/T OFF kgf/cm2   7.8 7.4 8.2
Oil temperature degC   52 50 54
0000001101
Pump speed r/min   900 900 900
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Timer stroke with S/T ON mm   2 1.7 2.3
Timer stroke with S/T OFF mm   3.4 3.2 3.6
Basic   *
Oil temperature degC   50 48 52
Remarks
OFF
 
_02
Pump speed r/min   900 900 900
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Timer stroke with S/T ON mm   1.7 1.3 2.1
Timer stroke with S/T OFF mm   3.4 3.1 3.7
Basic   *
Oil temperature degC   50 48 52
_03
Pump speed r/min   1200 1200 1200
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Timer stroke with S/T OFF mm   5.2 4.8 5.6
Oil temperature degC   50 48 52
_04
Pump speed r/min   2300 2300 2300
Boost pressure kPa   66.7 65.4 68
Boost pressure mmHg   500 490 510
Timer stroke with S/T OFF mm   9.8 9.3 10.2
Oil temperature degC   52 50 54
0000001201
Max. applied voltage V   8 8 8
Test voltage V   13 12 14
Timing setting
K dimension mm   3.3 3.2 3.4
KF dimension mm   7.22 7.12 7.32
MS dimension mm   1.8 1.7 1.9
BCS stroke mm   2.9 2.7 3.1
Control lever angle alpha deg.   23 19 27
Control lever angle beta deg.   42 37 47

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Test data 104761-2002
Adjustment of the potentiometer Adjusting method (dummy bolt method) 1. Position the control lever at the adjusting points in the table, hold the dummy bolt against the lever and fix. 2. In the fixed position, install the potentiometer so that the output voltage is V1 (supply voltage Vi). 3. After completing potentiometer installation, remove the dummy bolt. N:Pump speed P:Boost pressure Q:Injection quantity V:Output voltage C/L: control lever angle I:Idle position F:Full speed position M:Connecting diagram for the potentiometer K:Output R:Output when (2) and (3) connected.
----------
V1=3.2+-0.03V Vi=10V
----------
N1=600r/min Q1=16.9+-1.0mm3/st V1=3.2+-0.03V V2=1.03+-0.65V V3=8.03+-1.12V a=0deg b=42deg P=0kPa(0mmHg) Vi=10V

0000001901 M-CSD ADJUSTMENT

Test data 104761-2002
M-CSD adjustment 1. CSD adjustment Turn the lever (D) clockwise and adjust screw (B) so that the timer piston advance angle is a (L1). Then fix using the nut. 2. With intermediate lever screw (C)'s fixing lever (D) positioned as in 1., pull the intermediate lever in direction X. After confirming that it contacts the stop position, adjust so that screw (C) contacts lever (D) and then fix using the nut. (Intermediate lever status in 2.: full speed, indicates timer's a advance. Confirm that the timer piston advances to b deg when the intermediate lever is returned. 3. Fast idle adjustment Pull the intermediate lever in direction x to contact the stopper and adjust the screw (A) so that the gap between the idle set bracket and the idle screw is L2. Fix using the nut. The gap between the control lever at the idle position and the screw (A) must be L3. (E) control lever (F) intermediate lever
----------
a=3deg b=0deg L1=2.5mm L2=6+-0.05mm L3=(1.7mm)
----------
T1=6~9N-m(0.6~0.9kgf-m) T2=5~7N-m(0.5~0.7kgf-m) L2=6+-0.05mm

0000002001 DASHPOT ADJUSTMENT

Test data 104761-2002
Adjustment of the dash pot 1. Insert a block gauge L (thickness gauge) between the idle set bracket and the idle screw. 2. In the above condition, adjust so that the dashpot adjusting screw (A) contacts the pushrod. Then, fix using the nut. Record the dashpot return time t. a = alpha
----------
L=3.8+-0.05mm t=1.8+-0.5sec
----------
T=5~7N-m(0.5~0.7kgf-m) b=7.4deg L=3.8+-0.05mm




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