Information injection-pump assembly
BOSCH
F 01G 09U 052
f01g09u052
ZEXEL
101607-1112
1016071112
Rating:
Service parts 101607-1112 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:
101607-1112
as INJECTION-PUMP ASSEMBLY
Include in #2:
104746-6541
as _
Cross reference number
BOSCH
F 01G 09U 052
f01g09u052
ZEXEL
101607-1112
1016071112
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
*
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)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 = dd (non-injection rack position).
(3)Rack position = approximately ee.
(4)Free (at shipping)
(5)At hole above R = ff.
----------
aa=1400r/min bb=6.9-0.5mm cc=275r/min dd=(8.9)-0.5mm ee=15mm ff=40mm
----------
a=36.5deg+-5deg b=(25deg) c=13.5deg+-5deg
----------
aa=1400r/min bb=6.9-0.5mm cc=275r/min dd=(8.9)-0.5mm ee=15mm ff=40mm
----------
a=36.5deg+-5deg b=(25deg) c=13.5deg+-5deg
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=(0deg)
----------
aa=11deg
----------
a=(0deg)
Information:
Guidelines For Reusable Parts; Valves And Valve Springs, SEBF8002 and SEBF8034 have the procedure and specifications necessary for checking used valves and valve springs.(1) 4W2471 Spring for valves (outer) (new): Length under test force ... 53.24 mm (2.096 in)Test force ... 245 24 N (55 5 lb)Use again minimum load at length under test force ... 211 N (48 lb)Length of spring at valve open position ... 39.0 mm (1.54 in)Use again minimum load at valve open position ... 755 N (170 lb)Free length after test ... 59.5 mm (2.34 in)Outside diameter ... 37.31 mm (1.469 in)Spring must not be bent more than ... 2.10 mm (.083 in)(1) 4W2472 Spring for valves (inner) (new): Length under test force ... 50.24 mm (1.978 in)Test force ... 178 18 N (40 4 lb)Use again minimum load at length under test force ... 155 N (35 lb)Length of spring at valve open position ... 36.0 mm (1.42 in)Use again minimum load at valve open position ... 321 N (72 lb)Free length after test ... 65.7 mm (2.60 in)Outside diameter ... 25.13 mm (.989 in)Spring must not be bent more than ... 2.30 mm (.091 in)(2) Height to top of valve guide ... 27.2 .8 mm (1.07 .03 in)(3) Diameter of valve stem (new) ... 9.441 .01 mm (.3717 .0004 in)Use again minimum diameter of valve stems:Exhaust ... 9.408 mm (.3704 in)Inlet ... 9.408 mm (.3704 in)Bore in valve guide with guide installed in the head (new) ... 9.487 0.025 mm (.3735 .0010 in)Use again dimension for valve guide bore ... 9.538 mm (.3755 in)(4) Diameter of valve head: Exhaust valve ... 41.81 0.13 mm (1.646 .005 in)Inlet valve ... 44.98 0.13 mm (1.771 .005 in)(5) Angle of inlet valve face ... 29 1/4 1/4 degreesAngle of exhaust valve face ... 44 1/4 1/4 degrees (6) Depth of bore in head for valve seat insert ... 13.01 0.35 mm (.512 .014 in)(7) Diameter of valve seat insert for inlet valve ... 46.025 0.013 mm (1.8120 .0005 in) Bore in head for valve seat insert for inlet valve ... 45.949 0.025 mm (1.8090 .0010 in)Diameter of valve seat insert for exhaust valve ... 42.850 0.013 mm (1.6870 .0005 in)Bore in head for valve seat insert for exhaust valve ... 42.774 0.025 mm (1.6840 .0010 in)(8) Angle of face of inlet valve seat insert ... 30 1/4 1/2 degreesAngle of face of exhaust valve seat insert ... 44 3/4 1/2 degrees(9) Dimension from end of closed valve to machined face of head. Maximum permissible dimension:Below (recessed from) machined face ... 1.22 mm (.048 in)Above (extended from) machined face ... 0.20