104742-3001 ZEXEL F 01G 09W 0F9 BOSCH INJECTION-PUMP ASSEMBLY f01g09w0f9 1047423001 32a6527310

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09W 0F9 f01g09w0f9

ZEXEL 104742-3001 1047423001

MITSUBISHI-HEAV 32A6527310 32a6527310

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Cross reference number

BOSCH F 01G 09W 0F9 f01g09w0f9

ZEXEL 104742-3001 1047423001

MITSUBISHI-HEAV 32A6527310 32a6527310

Zexel num

Bosch num

Firm num

Name

104742-3001

F 01G 09W 0F9

32A6527310 MITSUBISHI-HEAV

INJECTION-PUMP ASSEMBLY
S4S-DT

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113orSAEJ967d

Test oil temperature degC 45 45 50

Nozzle 105780-0060

Bosch type code NP-DN0SD1510

Nozzle holder 105780-2150

Opening pressure MPa 13 13 13.3

Opening pressure kgf/cm2 133 133 136

Injection pipe 157805-7320

Injection pipe
Inside diameter - outside diameter - length (mm) mm 2-6-450

Joint assembly 157641-4720

Tube assembly 157641-4020

Transfer pump pressure kPa 20 20 20

Transfer pump pressure kgf/cm2 0.2 0.2 0.2

Direction of rotation (viewed from drive side)
Right R

(Solenoid timer adjustment condition)
With S/T O-ring; S/T OFF. OFF

Timer measuring device installation position
Low pressure side LOW PRESSURE SIDE

Injection timing adjustment

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 119.7 119.2 120.2

Difference in delivery mm3/st. 11

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_02

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 75.7 69.2 82.2

Oil temperature degC 48 46 50

Injection timing adjustment_03

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 119.7 117.2 122.2

Difference in delivery mm3/st. 11.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 126.5 121 132

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 123.5 118 129

Oil temperature degC 50 48 52

Injection quantity adjustment

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 5

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_02

Pump speed r/min 1425 1425 1425

Average injection quantity mm3/st. 6.5

Basic *

Oil temperature degC 50 48 52

Injection quantity adjustment_03

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 117.9 117.9

Oil temperature degC 50 48 52

Remarks
(check)

Governor adjustment

Pump speed r/min 595 595 595

Average injection quantity mm3/st. 8.1 6.1 10.1

Difference in delivery mm3/st. 3

Basic *

Oil temperature degC 50 48 52

Governor adjustment_02

Pump speed r/min 595 595 595

Average injection quantity mm3/st. 8.1 5.6 10.6

Difference in delivery mm3/st. 3.5

Basic *

Oil temperature degC 50 48 52

Timer adjustment

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 95 145

Basic *

Oil temperature degC 48 46 50

Remarks
Full

Timer adjustment_02

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 120 95 145

Oil temperature degC 48 46 50

Remarks
Full

Speed control lever angle

Pump speed r/min 595 595 595

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 50 48 52

Remarks
Magnet OFF at idling position

Speed control lever angle_02

Pump speed r/min 595 595 595

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 50 48 52

Remarks
Magnet ON at idling position and stop lever operate

0000000901

Pump speed r/min 1250 1250 1250

Overflow quantity with S/T ON cm3/min 540 410 670

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 1250 1250 1250

Pressure with S/T ON kPa 696 647 745

Pressure with S/T ON kgf/cm2 7.1 6.6 7.6

Pressure with S/T OFF kPa 530 510 550

Pressure with S/T OFF kgf/cm2 5.4 5.2 5.6

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

Stop lever angle_02

Pump speed r/min 900 900 900

Pressure with S/T OFF kPa 402 353 451

Pressure with S/T OFF kgf/cm2 4.1 3.6 4.6

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1100 1100 1100

Pressure with S/T OFF kPa 481 432 530

Pressure with S/T OFF kgf/cm2 4.9 4.4 5.4

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 1250 1250 1250

Pressure with S/T ON kPa 696 637 755

Pressure with S/T ON kgf/cm2 7.1 6.5 7.7

Pressure with S/T OFF kPa 530 501 559

Pressure with S/T OFF kgf/cm2 5.4 5.1 5.7

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

0000001101

Pump speed r/min 1250 1250 1250

Timer stroke with S/T ON mm 4.6 4.1 5.1

Timer stroke with S/T OFF mm 2.9 2.7 3.1

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

_02

Pump speed r/min 900 900 900

Timer stroke with S/T OFF mm 1.2 0.5 1.9

Oil temperature degC 50 48 52

_03

Pump speed r/min 1100 1100 1100

Timer stroke with S/T OFF mm 2.2 1.6 2.8

Oil temperature degC 50 48 52

_04

Pump speed r/min 1250 1250 1250

Timer stroke with S/T ON mm 4.6 3.9 5.3

Timer stroke with S/T OFF mm 2.9 2.5 3.3

Basic *

Oil temperature degC 50 48 52

Remarks
OFF

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

0000001401

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 94 92 96

Timer stroke TA mm 0.3 0 0.6

Timer stroke variation dT mm 2.6 2.6 2.6

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 112 110 114

Timer stroke TA mm 2.7 2.7

Timer stroke variation dT mm 0.2 0.2 0.2

Oil temperature degC 50 48 52

Remarks
(check)

_03

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 94 91.5 96.5

Timer stroke TA mm 0.3 0 0.8

Timer stroke variation dT mm 2.6 2.6 2.6

Basic *

Oil temperature degC 50 48 52

_04

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 25 22.5 27.5

Timer stroke TA mm 3.5 2.7 4.3

Timer stroke variation dT mm 0.6 0.6 0.6

Oil temperature degC 50 48 52

Timing setting

K dimension mm 3.1 3 3.2

KF dimension mm 5.5 5.4 5.6

MS dimension mm 0.9 0.8 1

Pre-stroke mm 0.45 0.43 0.47

Control lever angle alpha deg. 16 12 20

Control lever angle beta deg. 30 25 35

Test data Ex:

0000001801 TAMPER PROOF

Tamperproof installation procedure A:Position of break B:Rubber vibration damper C:Nut D:Cap E:Nut F:Nut G:Cap L1:Inspection dimension Fig. 1 Regulating valve seal 1) Target breaking torque T1 2) Maximum allowable breaking torque T2 3) Because the cap and the regulating valve are fixed using the MEC process, the bolt cannot be loosened after the bolt has been broken. Fig.2 Full load adjusting screw 1) Confirm the position of the rubber vibration damper (B) and then tighten nut (C) to the torque T3. Fig. 3 Maximum speed adjusting screw 1) Tighten nut (E) to the torque T4. 2) To prevent nut (E) from turning together, fix (E) using the tool, then tighten nut (F) to torque T4.
----------
L1=23~28mm T1=5~6.9N-m(0.5~0.69kgf-m) T2=9N-m(0.9kgf-m) T3=7~9N-m(0.7~0.9kgf-m) T4=6~9N-m(0.6~0.9kgf-m)
----------
L1=23~28mm

Information:

1. Defective Upper O-ring On Unit Injectors Or Leaking Unit Injector Using the fuel priming pump, pressurize the fuel system to 689 kPa (100 psi). Check for fuel on the top deck of the cylinder head (a small amount of leakage is normal from the injector plunger barrel area after 5 minutes of constant pressure). If fuel is found, drain the fuel supply manifold. Remove each unit injector (see 3176 Vehicular Diesel Engine Disassembly and Assembly, Form No. SENR4965), and check for a defective upper O-ring on the unit injector or if the unit injector itself is leaking.A bad injector to sleeve seat causes combustion gas leakage that can damage the injector O-rings. Inspect injector hold down bolt thread depth for a minimum of 25 mm (.984 in) of thread depth in the cylinder head.Testing of the injectors must be done off of the engine. Use the 1U6661 Pop (Injector) Tester Group with a 1U6663 Injector Holding Block, and a 1U6665 Power Supply, to test the injectors. For the test procedure refer to Special Instruction, Form No. SEHS8867, Using The 1U6661 Pop (Injector) Tester. For test specifications refer to Special Instruction, Form No. SEHS8804, Unit Injector Test Specifications for 1.7 Liter Engines. Inspect and repair as necessary the sealing surface (seat) of the injector sleeve in the cylinder head when removing and installing an injector. The injector sealing surface (seat) must be free of scratches or evidence of combustion products. If it is necessary to rework (ream) or replace the sleeve use 4C4054 Tool Group and refer to Special Instruction, Form No. SEHS9246, Using The 4C4054 Unit Injector Sleeve Replacement Tool Group.2. Injector Not Seated Properly A bad injector to sleeve seat causes combustion gas leakage that can damage the injector o-rings. Inspect injector hold down bolt thread depth for a minimum of 25 mm (.984 in) of thread depth in the cylinder head.Torque fuel injector hold down bolt to 33 7 N m (24 5 lb ft). Inspect and repair as necessary the sealing surface (seat) of the injector sleeve in the cylinder head when removing and installing an injector. The injector sealing surface (seat) must be free of scratches or evidence of combustion products. If it is necessary to rework (ream) or replace the sleeve use 4C4054 Tool Group and refer to Special Instruction, Form No. SEHS9246, Using The 4C4054 Unit Injector Sleeve Replacement Tool Group.3. Crack(s) In Cylinder Head Pressurize the fuel gallery and check for crack(s). Crack(s) between the cylinder head fuel passages and passages open to the crankcase will allow fuel to enter the crankcase.4. Porosity In Cylinder HeadPressurize the fuel gallery and check for porosity. Leakage may be due to the proximity of the hole to internal fuel passages.