Information injection-pump assembly
BOSCH
F 01G 09U 053
f01g09u053
ZEXEL
101607-1141
1016071141
Rating:
Service parts 101607-1141 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
Cross reference number
BOSCH
F 01G 09U 053
f01g09u053
ZEXEL
101607-1141
1016071141
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=24deg+-5deg b=(44deg)+-3deg
----------
aa=29mm
----------
a=24deg+-5deg b=(44deg)+-3deg
Stop lever angle
N:Pump normal
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).
----------
aa=1400r/min bb=6.9-0.5mm cc=275r/min dd=(8.9)-0.5mm
----------
a=11.5deg+-5deg b=(29deg)+-5deg
----------
aa=1400r/min bb=6.9-0.5mm cc=275r/min dd=(8.9)-0.5mm
----------
a=11.5deg+-5deg b=(29deg)+-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
----------
0000001601 LEVER
(A) Idle
(B) Full speed
(C) Base lever
(D) Accelerator lever
(E) Accelerator lever delivery position
1. Measure speed lever angle
(1)Measure the angle when the accelerator lever (D) contacted the base lever (C) at a.
----------
----------
b=(44deg)+-3deg c=24deg+-5deg
----------
----------
b=(44deg)+-3deg c=24deg+-5deg
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) Torque for bolt that holds the impeller ... 39 3 N m (28 2 lb ft)(2) Shaft diameter at carbon seal assembly seat area must be ... 19.10 0.05 mm (.752 .002 in) Use 4C9500 Quick Cure Primer to clean the water pump shaft and the ceramic ring seal counterbore in the pump housing.(3) Ring and water seal. Use a 125-9622 Seal Installation Tool and hand pressure to install the rubber seal and ceramic ring as a unit in the pump housing bore. Make sure the identification mark (holes or groove) on the ceramic ring face is installed inside the rubber seal.(4) Seal assembly. a. Remove the spring from the seal.b. Put clean water on the seal assembly as the only lubrication for assembly. Do not get any grease or oil on the seal faces.c. Do not stretch the rubber of the seal assembly at installation. If the seal is stretched, the service life is shortened.d. Use a 125-9622 Seal Installation Tool and hand pressure to install the seal assembly on the pump shaft until the carbon face makes light contact with the smooth face of the ceramic ring. The carbon seal assembly must rotate with the water pump shaft. Do not use any lubricant (except clean water) that will reduce the friction between the seal and the shaft.e. Install the carbon seal assembly spring.(5) Oil seal. Put a small amount of clean engine oil on the lip of the seal at assembly. Install it with the lip toward the bearings as shown.(6) Torque for bolt that holds the gear ... 215 40 N m (160 30 lb ft)Water Pump (135-4925 and 135-4926)
(1) With flat side towards housing install oil seal flush with housing using a suitable driver. DO NOT lubricate lip of seal.(2) Install Shaft. Shaft diameter at unitized seal assembly must be ... 19.10 .01 mm (.752 .0004 in). Using a 138-9299 Installation Tool over the shaft with the chamfer facing out, carefully insert the shaft into the oil seal. Position the shaft to center the oil seal lips on the shaft running surface. Then remove installation tool from shaft.(3) Install bearings. Slide the bearing assembly over the shaft and into the housing. Torque the bearing retainer plate bolts to ... 25 6 N m (19 4 lb ft)(4) Torque for gear retaining bolt ... 215 40 N m (158 30 lb ft)(5) Unitized seal. Using a 139-0088 Installation Tool and a suitable press to install the seal onto the pump shaft and into the housing bore, insure that the seal is fully seated in the housing bore. DO NOT use a hammer to install the seal as damage to ceramic sealing face will occur.(6) Bolt torque for the impeller retaining bolts is ... 39 3 N m (28 2 lb ft)
(1) With flat side towards housing install oil seal flush with housing using a suitable driver. DO NOT lubricate lip of seal.(2) Install Shaft. Shaft diameter at unitized seal assembly must be ... 19.10 .01 mm (.752 .0004 in). Using a 138-9299 Installation Tool over the shaft with the chamfer facing out, carefully insert the shaft into the oil seal. Position the shaft to center the oil seal lips on the shaft running surface. Then remove installation tool from shaft.(3) Install bearings. Slide the bearing assembly over the shaft and into the housing. Torque the bearing retainer plate bolts to ... 25 6 N m (19 4 lb ft)(4) Torque for gear retaining bolt ... 215 40 N m (158 30 lb ft)(5) Unitized seal. Using a 139-0088 Installation Tool and a suitable press to install the seal onto the pump shaft and into the housing bore, insure that the seal is fully seated in the housing bore. DO NOT use a hammer to install the seal as damage to ceramic sealing face will occur.(6) Bolt torque for the impeller retaining bolts is ... 39 3 N m (28 2 lb ft)