101401-4781 ZEXEL F 01G 09U 002 BOSCH INJECTION-PUMP ASSEMBLY f01g09u002 1014014781 8971147590

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09U 002 f01g09u002

ZEXEL 101401-4781 1014014781

ISUZU 8971147590 8971147590

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106671-8136 as _

Cross reference number

BOSCH F 01G 09U 002 f01g09u002

ZEXEL 101401-4781 1014014781

ISUZU 8971147590 8971147590

Zexel num

Bosch num

Firm num

Name

101401-4781

F 01G 09U 002

8971147590 ISUZU

INJECTION-PUMP ASSEMBLY
4HG1 * 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 134424-3920

Overflow valve opening pressure kPa 127 107 147

Overflow valve opening pressure kgf/cm2 1.3 1.1 1.5

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 1-3-4-2

Pre-stroke mm 4.1 4.05 4.15

Rack position
Point A R=A

Beginning of injection position
Governor 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 11.1

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 68.5 66.9 70.1

Max. variation between cylinders % 0 -4 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 285 285 285

Average injection quantity mm3/st. 10.5 9.2 11.8

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.1)

Pump speed r/min 960 960 960

Average injection quantity mm3/st. 68.5 67.5 69.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.55

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 89.5 85.5 93.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.2

Pump speed r/min 520 520 520

Average injection quantity mm3/st. 47.6 43.6 51.6

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.15

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 76 72 80

Fixing the lever *

Timer adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 6 5.5 6.5

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.
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T1=N20
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=43deg+-5deg b=42deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=64mm
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a=20deg+-5deg b=29deg+-5deg

0000001501 FICD

(A) applied negative pressure (B) Screw (c) Nut 1. Set the actuator as described below. (1)Confirm that there is clearance between the actuator lever and the speed lever. (2)Loosen the nut (C). (3)Push in the screw (B). (4)Apply P1 from the actuator (A) part. (5)Pull out the screw (B) slowly. (6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra. (7)Torque the nut (C) to T1. (8)Apply P2 several times. (9)Confirm that the actuator functions normally. (10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
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P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=400r/min Ra=9.3+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
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L=(5)mm

0000001601 RACK SENSOR

Rack sensor adjustment 1. Flange type rack sensor (rack sensor adjustment -5*20) (1)These types of rack sensors do not need adjustment. Confirm the performance with the following procedures. (2)Mount the rack sensor main body to the pump main body. (3)Fix the pump lever at full. (4)At supply voltage V1, pump speed N1 and rack position Ra, confirm that the amp's output voltage is Vist. (5)Move the pump lever two or three times. (6)Set again to full. (7)Confirm that the amplifier output voltage is Vist. (8)Fix the caution plate to the upper part of the rack sensor. (For those without the caution plate instructions, make sure the nameplate of the rack sensor carries the "Don't hold here" caution.) (9)Apply red paint to the rack sensor mounting bolts (2 places).
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V1=5+-0.01V N1=960r/min Ra=R1(11.1)mm Vist=2.33+-0.28V
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Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)Timing device stamping (4)At the No 1 cylinder's beginning of injection, align with the aligning mark seen through the bracket's check hole and mark the A/T's bevel C1. (5)B.T.D.C.: aa
----------
aa=7deg
----------
a=(60deg) b=(85deg)

Information:

(3) Check the unit seals installed in the impeller and water pump case for damage and wear. If defects are evident, or when water leaks during operation, replace the unit seals with new ones. Whenever the unit seal is removed, it must be replaced with a new one. (4) Using a gear puller or press, remove the ball bearings. Do not remove the ball bearing except for replacement. (5) When the impeller and flange are removed from the water pump shaft, it may result in insufficient interference. If the interference is below the specification even reassembly is two times or less they must be replaced with new ones.Reassembly
5.3 Thermostat
Removal and installation
Do not remove the thermostat case and front hanger unless they cause water leak or other defects.Inspection
Agitate water in the container with the stirrer to obtain uniform temperature. For the inspection, use the following procedures. (1) Slowly heat water to the thermostat valve opening temperature. Keep this condition for about five minutes and make sure that the valve is open.(2) Raise the water temperature up to 90°C. Keep the condition for five minutes and measure the lift of pellet.(3) Lower temperature down to 65°C or below and ensure that the valve is fully closed. If the thermostat is found defective in any of the above items, replace it with a new one. Support the thermostat so that the heat source will not directly heat the thermostat.5.4 Radiator
Inspection (1) Using a copper wire or similar device, remove dirt, mud, and bugs from the front of radiator core with care to prevent damage to tubings. (2) Connect a hose to one of the radiator ports, cap the other port, and immerse the radiator into water. Using a radiator cap tester, force the compressed air under the specified inspection pressure from the hose end to check for leaks.If there is a leak, resolder the point of leakage or replace the radiator.(3) Inspection of Radiator Cap Check the spring tension and sealing condition of the pressure valve and vent valve. If defective, replace. Check the pressure valve opening pressure, using a radiator cap tester.5.5 Inspection and Adjustment of V-belt Tension
Adjust the belt tension to obtain the specified belt deflection when the center of each belt is pressed with a force of approximately 98 N (10 kgf). 1. A slack belt can be a cause of overheating and undercharge.2. An excessively tight belt may result in damaged bearings and belts.3. When paired belts are to be replaced, be sure to replace both.5.6 Cleaning of Cooling System
If the radiator is used for a long time, rust, scale, mud, etc. are deposited inside, resulting in overheat. Clean the cooling system with city water by using the following procedures.The city water to be used should have the following properties.Required properties of city water 1. Use a cleaning solution if the radiator is seriously obstructed or coolant is seriously contaminated.2. When the cooling system is cleaned or washed with water, make sure that the coolant temperature is