101607-6080 ZEXEL F 01G 09U 05G BOSCH INJECTION-PUMP ASSEMBLY f01g09u05g 1016076080

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09U 05G f01g09u05g

ZEXEL 101607-6080 1016076080

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101402-7500 as _

Cross reference number

BOSCH F 01G 09U 05G f01g09u05g

ZEXEL 101607-6080 1016076080

Zexel num

Bosch num

Firm num

Name

101607-6080
101607-6081

F 01G 09U 05G

INJECTION-PUMP ASSEMBLY
* 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 131424-8420

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

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 11.7

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 77.8 75.5 80.1

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 800 800 800

Each cylinder's injection qty mm3/st. 10.8 9.2 12.4

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.7)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77.8 76.8 78.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 88.7 84.7 92.7

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.4

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 56.3 52.3 60.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 91 81 101

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1080

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 2.5 2.5 2.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min 1390

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. (3)RACK LIMIT
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T1=H34
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
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a=18.5deg+-5deg b=(42deg)+-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 delivery)
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aa=1450r/min bb=7.2-0.5mm cc=275r/min dd=(8.8)mm ee=15mm
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a=36.5deg+-5deg b=(25deg) c=13deg+-5deg

0000001501 LEVER

(A) Accelerator lever stopper bolt (B) Link (c) Nut (D) Lever (E) Pin (f) lever (G) Stopper bolt (H) Return spring (J) Pin (E) contacts lever. (K) Load sensor terminal (1)Black (2)Blue-yellow (3)Blue-red Setting the accelerator lever angle, load sensor adjustment 1. Accelerator lever setting method (1)Position the speed lever against the idle stopper bolt and fix. (2)Screw in the accelerator lever stopper bolt (A) and back off the stopper bolt (A) from the position where the accelerator lever pin contacts the speed lever and set. (Gap: approx. 1 mm) Tightening torque: 4.9~7 N.m {0.5~0.7 kgf.m} 2. Load sensor adjustment (See fig 1) (1)Load sensor output measuring circuit Apply DC5+-0.01V to the load sensor terminals and measure the output voltage. (2)Load sensor output adjustment procedure Hold the speed lever against the full side stopper bolt and fix. Adjust the load sensor output voltage to VF = 0.417+-0.1 V using the link (B) and then fix temporarily using nut (C). Turn the speed lever from the idle side to the full side and confirm that output voltage VF = 0.417+-0.1 V is obtained. Confirm several times and then fix using nut (C). Tightening torque: 3.4~4.9 N.m {0.35~0.5 kgf.m} 3. Setting the step motor's idle side stopper bolt After adjustment in previous 1 and 2, position speed lever against idle stopper bolt and fix. Then, screw in stopper bolt G until step motor lever D's pin E contacts lever F. Back off 10+2 deg (approx. 3.5 mm) from this position and fix G. (See fig. 3) 4. Speed lever return confirmation (1)Remove return spring (H) and confirm that the speed lever is returned to the idle position by the torsion spring. (2)Reinstall the return spring (H) in its original position.
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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)-
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aa=10deg
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a=(3deg)

Information:

Highly Recommended
The following equipment is highly recommended:
The Fluke 741B Multimeter is desired. 163-0096 Diagnostic and Calibration Tool
Ladder Viewer Diagnostic Software, YERA0162
The 4C-4029 Adjusting Tool Alternate Recommendations
The Milliampere Loop Simulator and TesterRTD Simulator and Tester Omega CL308Thermocouple Simulator and Tester Omega CL477The Simulator and Tester Omega CL26 for RTD and ThermocoupleThe Fluke 87 9U-7330 Digital Multimeter The Caterpillar Multimeter is also acceptable. 6V-7070 Digital Multimeter The attachments for the Fluke multimeter are in the following list:
Thermocouple Module 80TK is for reading thermocouples.
Immersion Probe 80PK2A can be used with self-sealing adapters.
8T-5200 Signal Generator/Counter is for checking the calibration of the speed switch and for simulating engine speed for the PLC.General Diagnostic Tools For the 3600
Reference: Engine News October 1990"Engine Commissioning and Diagnostic Tooling Kit".The following tools are used for measuring the pressures of the engine. The tools are also use for measuring the temperatures of the engine.
1U-5470 Engine Pressure Group
6V-9130 Temperature Adapter The following list contains the self-sealing adapters that are used for the installation of test ports in piping systems. The sizes of the adapters and the quantities of the adapters depend on the number of test ports that are needed.
5P-2725 Probe Seal Adapter
5P-3591 Probe Adapter
4C-4545 Probe Adapter Group
1U-8865 Infrared Thermometer
139-2788 Crimping Tool A Carrier-Oehler Calibration Pump is used in order to calibrate the setup for the alarms. The pump is also used in order to calibrate the shutdown setup.Contact information for the calibration pump:Carrier-Oehler Company
P.O. Box 40
16965 S. Vincennes
South Holland, Illinois USA 60473
ph: (708) 339-8200, fax: (708) 339-9830