101603-8483 ZEXEL F 01G 09U 049 BOSCH INJECTION-PUMP ASSEMBLY f01g09u049 1016038483 8943957503

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09U 049 f01g09u049

ZEXEL 101603-8483 1016038483

ISUZU 8943957503 8943957503

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Service parts 101603-8483 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6260

3. GOVERNOR 105932-0921

4. SUPPLY PUMP

105210-6080

5. AUTOM. ADVANCE MECHANIS 105672-5250

6. COUPLING PLATE 105661-1140

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7740

11. Nozzle and Holder 8-94393-335-1

12. Open Pre:MPa(Kqf/cm2) 16.2{165}/18.1{185}

13. NOZZLE-HOLDER 105030-4610

14. NOZZLE 105025-0080

15. NOZZLE SET

Include in #1:

101603-8483 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5382 as _

Cross reference number

BOSCH F 01G 09U 049 f01g09u049

ZEXEL 101603-8483 1016038483

ISUZU 8943957503 8943957503

Zexel num

Bosch num

Firm num

Name

101603-8483

F 01G 09U 049

8943957503 ISUZU

INJECTION-PUMP ASSEMBLY
6HH1-S * K 14BF PE6AD PE

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 131424-4920

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 1-5-3-6- 2-4

Pre-stroke mm 4.7 4.65 4.75

Rack position
After adjusting injection quantity. R=A

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 13

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 86.5 84.9 88.1

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 -

Rack position 9.6+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9.4 8.1 10.7

Max. variation between cylinders % 0 -14 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 86.5 85.5 87.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.15

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 95.5 92.3 98.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 77.5 74.3 80.7

Fixing the lever *

Timer adjustment

Pump speed r/min 905--

Advance angle deg. 0 0 0

Load 3/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 855

Advance angle deg. 0.3

Load 3/5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1.5 1 2

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1110

Advance angle deg. 1.5 1 2

Load 3/5

Timer adjustment_05

Pump speed r/min 1450

Advance angle deg. 7 6.5 7.5

Load 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=K09
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=60mm
----------
a=28.5deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=46.5mm
----------
a=34.5deg+-5deg b=40deg+-5deg

0000001501 I/P WITH LOAD PLUNGER ADJ

Plunger assembly number: PL (stamping: ST) 1. Adjustment procedures (1)Insert the pre-stroke adjusting shims L1 for each cylinder. (2)Adjust injection quantity.(max. var. bet. cyl. idling a1, full a2) (3)At basic point A, adjust so that the pre-stroke is L2. (4)Reconfirm the injection quantity.
----------
PL=131153-9020 ST=A769 L1=1mm L2=4.7+-0.05mm a1=+-14% a2=+-2.5%
----------

0000001601 AIR CYLINDER

1. (1) Set the speed lever to idle. (2)Screw in air cylinder (A) (3)Set the clearance from the speed lever (B) at approximately L.
----------
L=1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)At rack position = bb
----------
aa=6deg bb=R1(13)mm
----------
a=(150deg)

Information:

GUIDELINES FOR REUSABLE PARTS; VALVES AND VALVE SPRINGS, Form SEBF8002, has the procedure necessary for checking used valves and valve springs.(1) 4N5906 Spring for valves (new): Length under test force ... 2.165 in.(54.9 mm)Test force ... 77.0 7.6 lb.(344 34 N)Use again minimum load at length under test force ... 65.4 lb.(291 N)Length of spring at valve open position ... 1.690 in.(42.93 mm)Use again minimum load at valve open position ... 183.6 lb.(817 N)Free length after test ... 2.47 in.(62.7 mm)Outside diameter ... 1.250 in.(31.75 mm)Spring must not be bent more than ... .086 in.(2.18 mm)(2) Height to top of valve guide ... 1.27 .03 in.(32.3 0.8 mm)(3) Diameter of valve stem (new) ... .3717 .0003 in.(9.441 0.008 mm) Use again minimum:4N5653 Exhaust ... Do Not Use Again4N5654 Intake ... .3704 in.(9.408 mm)Bore in valve guide with guide installed in the head (new) ... .3735 .0010 in.(9.487 0.025 mm)(4) Diameter of valve head: Exhaust valve ... 1.646 .005 in.(41.81 0.13 mm)Intake valve ... 1.771 .005 in.(44.98 0.13 mm)(5) Angle of intake valve face ... 291/4° 1/4°Angle of exhaust valve face ... 441/4° 1/4° (6) Depth of bore in head for valve seat insert ... .512 .015 in.(13.00 0.38 mm)(7) Diameter of valve seat insert for exhaust valve ... 1.6870 .0005 in.(42.850 0.013 mm) Bore in head for valve seat insert for exhaust valve ... 1.684 .001 in.(42.77 0.03 mm)Diameter of valve seat insert for intake valve ... 1.8120 .0005 in.(46.025 0.013 mm)Bore in head for valve seat insert for intake valve ... 1.809 .001 in.(45.95 0.03 mm)(8) Angle of face of intake valve seat insert ... 301/4° 1/2°Angle of face of exhaust valve seat insert ... 451/4° 1/2°(9) Dimension from top of closed valve to face of head: Maximum permissible dimension for intake and exhaust ... .048 in.(1.22 mm)Minimum permissible dimension for intake and exhaust ... .008 in.(0.20 mm)(10) Outside diameter of the face of the valve seat insert: Exhaust seat ... 1.591 .005 in.(40.41 0.13 mm)Intake seat ... 1.734 .005 in.(44.04 0.13 mm)(11) "Use again" thickness of valve lip: Exhaust valve ... .080 in.(2.03 mm)Intake valve ... .099 in.(2.51 mm)