Information injection-pump assembly
BOSCH
F 01G 09U 051
f01g09u051
ZEXEL
101607-1111
1016071111
Rating:
Service parts 101607-1111 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME076615
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/21.6{220}
15.
NOZZLE SET
Include in #1:
101607-1111
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-6540
as _
Cross reference number
BOSCH
F 01G 09U 051
f01g09u051
ZEXEL
101607-1111
1016071111
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-5-3-6-
2-4
Pre-stroke
mm
3.2
3.15
3.25
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.6
Pump speed
r/min
850
850
850
Each cylinder's injection qty
mm3/st.
72.5
70.3
74.7
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.
8.3
7.1
9.5
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.6)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
72.5
71.5
73.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.15
Pump speed
r/min
1400
1400
1400
Average injection quantity
mm3/st.
79.5
75.5
83.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.65
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
71.5
67.5
75.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
14.8+-0.
2
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
120
100
140
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1150
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.9
0.4
1.4
Timer adjustment_03
Pump speed
r/min
1380
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=F24
----------
----------
T1=F24
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=10deg+-5deg b=(44deg)+-3deg
----------
aa=29mm
----------
a=10deg+-5deg b=(44deg)+-3deg
Stop lever angle
N:Engine manufacturer's normal use
S:Stop the pump.
(1)Pump speed = aa and rack position = bb (non-injection rack position)
(2)Set the stopper bolt (confirm non-injection).
(3)Corresponding to rack position = cc.
(4)Free (at shipping)
(5)Use the hole above R = dd
----------
aa=1400r/min bb=6.9-0.5mm cc=15mm dd=40mm
----------
a=38.5deg+-5deg b=(27deg) c=15.5deg+-3deg
----------
aa=1400r/min bb=6.9-0.5mm cc=15mm dd=40mm
----------
a=38.5deg+-5deg b=(27deg) c=15.5deg+-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
----------
----------
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=11deg
----------
a=(1deg)
----------
aa=11deg
----------
a=(1deg)
Information:
(1) Gear. If new gear is required, replace camshaft assembly. The heat treatment of the gear is damaged if heated.(2) Diameter of the surfaces (journals) for the camshaft bearings (new) ... 69.850 0.013 mm (2.7500 .0005 in) Bore in front bearing for the camshaft (after assembly) ... 69.969 0.048 mm (2.7547 .0019 in)Bore in the other six bearings for the camshaft (after assembly) ... 69.982 0.061 mm (2.7552 .0024 in)(3) Thickness of thrust plate (new) ... 4.65 0.03 mm (.183 .001 in) End play of the camshaft ... 0.10 to 0.26 mm (.004 to .010 in)(4) Camshaft. (5) Height of camshaft lobes.To find lobe height, use the procedure that follows:A. Measure camshaft lobe height (5).B. Measure base circle (7).C. Subtract base circle (STEP B) from lobe height (STEP A). The difference is actual lobe lift (6).D. Specified camshaft lobe lift (6) is: Camshaft Assemblya. Exhaust lobe ... 10.5 mm (.413 in)b. Inlet lobe ... 10.5 mm (.413 in)Maximum permissible difference between actual lobe lift (STEP C) and specified lobe lift (STEP D) is 0.13 mm (.005 in)Inlet Valve Timing
1. Check the No. 1 inlet valve lash with the engine stopped. The valve lash must be 0.30 to 0.46 mm (.012 to .018 in). If the valve lash is not in this range, adjust the lash to 0.38 mm (.015 in).2. Mark Top Center Position of the crankshaft on the vibration damper or pulley.3. Use a dial indicator to measure the inlet valve movement.4. Rotate the crankshaft in the direction of normal engine rotation. Stop when the inlet valve is 1.91 mm (.075 in) off its seat in the opening sequence.At this point the crankshaft Top Center Position Mark must be ... 5 2 degrees After Top CenterChecking Valve-Camshaft Timing (field procedure)
The following procedure will simplify the checking of the camshaft timing procedures.1. Set the No. 3 inlet bridge adjustment. Refer to SENR6547 (Testing And Adjusting).2. Set the No. 3 inlet valve lash. Refer to SENR6547 (Testing And Adjusting).3. Install the bolt in the flywheel with No. 1 piston at top center.4. Install the dial indicator (magnetic base) to No. 3 inlet bridge.5. Remove the bolt from the flywheel.6. Set the indicator at zero and rotate the engine in the normal direction of operation (counterclockwise as viewed from the flywheel end) until dial travel stops.The correct setting should be ... 14.21 0.25 mm (.560 .010 in)
1. Check the No. 1 inlet valve lash with the engine stopped. The valve lash must be 0.30 to 0.46 mm (.012 to .018 in). If the valve lash is not in this range, adjust the lash to 0.38 mm (.015 in).2. Mark Top Center Position of the crankshaft on the vibration damper or pulley.3. Use a dial indicator to measure the inlet valve movement.4. Rotate the crankshaft in the direction of normal engine rotation. Stop when the inlet valve is 1.91 mm (.075 in) off its seat in the opening sequence.At this point the crankshaft Top Center Position Mark must be ... 5 2 degrees After Top CenterChecking Valve-Camshaft Timing (field procedure)
The following procedure will simplify the checking of the camshaft timing procedures.1. Set the No. 3 inlet bridge adjustment. Refer to SENR6547 (Testing And Adjusting).2. Set the No. 3 inlet valve lash. Refer to SENR6547 (Testing And Adjusting).3. Install the bolt in the flywheel with No. 1 piston at top center.4. Install the dial indicator (magnetic base) to No. 3 inlet bridge.5. Remove the bolt from the flywheel.6. Set the indicator at zero and rotate the engine in the normal direction of operation (counterclockwise as viewed from the flywheel end) until dial travel stops.The correct setting should be ... 14.21 0.25 mm (.560 .010 in)