104769-2191 ZEXEL F 01G 09W 0BH BOSCH INJECTION-PUMP ASSEMBLY f01g09w0bh 1047692191

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09W 0BH f01g09w0bh

ZEXEL 104769-2191 1047692191

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Cross reference number

BOSCH F 01G 09W 0BH f01g09w0bh

ZEXEL 104769-2191 1047692191

Zexel num

Bosch num

Firm num

Name

104769-2191
104769-2192

F 01G 09W 0BH

INJECTION-PUMP ASSEMBLY
* K

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

Injection timing adjustment

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 31.7 31.3 32.1

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Remarks
Full

Injection timing adjustment_02

Pump speed r/min 900 900 900

Boost pressure kPa 33.3 32 34.6

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 39 38.6 39.4

Difference in delivery mm3/st. 2

Basic *

Oil temperature degC 50 48 52

Remarks
CBS

Injection timing adjustment_03

Pump speed r/min 600 600 600

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 31.7 30.7 32.7

Oil temperature degC 50 48 52

Injection timing adjustment_04

Pump speed r/min 900 900 900

Boost pressure kPa 33.3 32 34.6

Boost pressure mmHg 250 240 260

Average injection quantity mm3/st. 39 38 40

Difference in delivery mm3/st. 2.5

Basic *

Oil temperature degC 50 48 52

Injection timing adjustment_05

Pump speed r/min 1200 1200 1200

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 43.9 41.9 45.9

Oil temperature degC 50 48 52

Injection timing adjustment_06

Pump speed r/min 1800 1800 1800

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 42.8 40.3 45.3

Oil temperature degC 50 48 52

Injection timing adjustment_07

Pump speed r/min 2200 2200 2200

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 42.5 39.5 45.5

Oil temperature degC 52 50 54

Injection quantity adjustment

Pump speed r/min 2300 2300 2300

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 35.8 34.8 36.8

Basic *

Oil temperature degC 52 50 54

Injection quantity adjustment_02

Pump speed r/min 2300 2300 2300

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 35.8 32.8 38.8

Oil temperature degC 52 50 54

Injection quantity adjustment_03

Pump speed r/min 2400 2400 2400

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 27.4 22.4 32.4

Difference in delivery mm3/st. 5

Oil temperature degC 52 50 54

Injection quantity adjustment_04

Pump speed r/min 2700 2700 2700

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Average injection quantity mm3/st. 3

Oil temperature degC 55 52 58

Governor adjustment

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 7.6 6.6 8.6

Difference in delivery mm3/st. 0.9

Basic *

Oil temperature degC 48 46 50

Governor adjustment_02

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 7.6 5.6 9.6

Difference in delivery mm3/st. 1.4

Basic *

Oil temperature degC 48 46 50

Governor adjustment_03

Pump speed r/min 500 500 500

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 3

Oil temperature degC 48 46 50

Boost compensator adjustment

Pump speed r/min 1200 1200 1200

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 12.8 7.8 17.8

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 8.4 8.4 8.4

Boost compensator adjustment_02

Pump speed r/min 900 900 900

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 16.2 9.7 22.7

Oil temperature degC 50 48 52

Lever angle (shim thickness) mm 8.4 8.4 8.4

Timer adjustment

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 38 38

Basic *

Oil temperature degC 48 46 50

Timer adjustment_02

Pump speed r/min 100 100 100

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 38 38

Oil temperature degC 48 46 50

Speed control lever angle

Pump speed r/min 350 350 350

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 48 46 50

Remarks
Magnet OFF at idling position

Speed control lever angle_02

Pump speed r/min 900 900 900

Boost pressure kPa 46.9 45.6 48.2

Boost pressure mmHg 352 342 362

Average injection quantity mm3/st. 0 0 0

Oil temperature degC 50 48 52

Remarks
Magnet OFF at full-load position

0000000901

Pump speed r/min 900 900 900

Boost pressure kPa 46.9 45.6 48.2

Boost pressure mmHg 352 342 362

Overflow quantity cm3/min 390 260 520

Oil temperature degC 50 48 52

Stop lever angle

Pump speed r/min 900 900 900

Boost pressure kPa 46.9 45.6 48.2

Boost pressure mmHg 352 342 362

Pressure kPa 373 344 402

Pressure kgf/cm2 3.8 3.5 4.1

Basic *

Oil temperature degC 50 48 52

Stop lever angle_02

Pump speed r/min 900 900 900

Boost pressure kPa 46.9 45.6 48.2

Boost pressure mmHg 352 342 362

Pressure kPa 372.5 333 412

Pressure kgf/cm2 3.8 3.4 4.2

Basic *

Oil temperature degC 50 48 52

Stop lever angle_03

Pump speed r/min 1800 1800 1800

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Pressure kPa 578.5 539 618

Pressure kgf/cm2 5.9 5.5 6.3

Oil temperature degC 50 48 52

Stop lever angle_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Pressure kPa 706 667 745

Pressure kgf/cm2 7.2 6.8 7.6

Oil temperature degC 52 50 54

0000001101

Pump speed r/min 900 900 900

Boost pressure kPa 46.9 45.6 48.2

Boost pressure mmHg 352 342 362

Timer stroke mm 1.3 1.1 1.5

Basic *

Oil temperature degC 50 48 52

_02

Pump speed r/min 900 900 900

Boost pressure kPa 46.9 45.6 48.2

Boost pressure mmHg 352 342 362

Timer stroke mm 1.3 1 1.6

Basic *

Oil temperature degC 50 48 52

_03

Pump speed r/min 1800 1800 1800

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Timer stroke mm 4.9 4.3 5.5

Oil temperature degC 50 48 52

_04

Pump speed r/min 2300 2300 2300

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Timer stroke mm 6.85 6.3 7.4

Oil temperature degC 52 50 54

_05

Pump speed r/min 2500 2500 2500

Boost pressure kPa 64 62.7 65.3

Boost pressure mmHg 480 470 490

Timer stroke mm 6.95 6.5 7.4

Oil temperature degC 55 52 58

0000001201

Max. applied voltage V 8 8 8

Test voltage V 13 12 14

Timing setting

K dimension mm 3.3 3.2 3.4

KF dimension mm 6.64 6.54 6.74

MS dimension mm 1.8 1.7 1.9

BCS stroke mm 3.9 3.8 4

Control lever angle alpha deg. 23 19 27

Control lever angle beta deg. 39 34 44

Test data Ex:

0000001801 POTENTIOMETER ADJUSTMENT

Potentiometer adjustment 1. Applied voltage: Vi 2. Boost pressure = P1kPa {P2 mmHg} 3. Set the control lever at the adjusting point. Position the dummy bolt against the lever and fix. 4. Assemble the potentiometer to obtain output voltage V1 (V) at the fixed position. 5. After mounting the potentiometer, remove the dummy bolt. A:Adjusting point B:Performance standards C:Control lever angle D:ON, OFF switch standard E:OFF-->ON F:OFF-->ON G:Applied voltage N:Pump speed Vo:Output voltage Q:Injection quantity C1:Idle C2:Full speed
----------
V1=4.32+-0.03V Vi=10V P1=0kPa P2=0mmHg
----------
N1=1200r/min N2=-r/min N3=-r/min V1=4.32+-0.03V V2=Measure V V3=Measure V Q1=14+-1cm3/1,000st Q2=-cm3/1,000st Q3=-cm3/1,000st C3=- C4=- G=10V

0000001901 M-CSD ADJUSTMENT

M-CSD adjustment 1. Move the lever E clockwise and when it contacts the stopper D, adjust screw B so that the timer piston advance is a (L1). Then, fix using the nut. 2. With intermediate lever screw (C)'s fixing lever (E) positioned as in 1., pull the intermediate lever in direction X. After confirming that it contacts the stop position, adjust so that screw (C) contacts lever (E) and then fix using the nut. (In condition (2), intermediate lever: full speed position, at timer advance a.) Confirm that the timer piston advances to b deg when the intermediate lever is returned. 3. Fast idle adjustment Pull the intermediate lever in direction x to contact the stopper and adjust the screw (A) so that the gap between the idle set bracket and the idle screw is L2. Fix using the nut. The gap between the control lever at the idle position and the screw (A) must be L3. (F) Control lever (G) Intermediate lever
----------
a=2deg b=0deg L1=1.6mm L2=6+-0.5mm L3=(1.7mm)
----------
T1=6~9N-m(0.6~0.9kgf-m) T2=5~7N-m(0.5~0.7kgf-m) L2=6+-0.5mm

0000002001 DASHPOT ADJUSTMENT

Adjustment of the dash pot 1. Insert a block gauge L (thickness gauge) between the idle set bracket and the idle screw. 2. In the above condition, adjust so that the dashpot adjusting screw (A) contacts the pushrod. Then, fix using the nut. Record the dashpot return time t. a = alpha
----------
L=3.8+-0.05mm t=1.8+-0.5sec
----------
T=5~7N-m(0.5~0.7kgf-m) b=7.4deg L=3.8+-0.05mm

Information:

1. Remove plug (1) from the fuel injection pump housing.2. Use Tool (D) to loosen nut (2) for the fuel injection pump to be removed. Disconnect the fuel injection line nuts, and remove the felt washer. 3. Install Tool (A) in the fuel pump housing as shown with the square end down. Use a small amount of hand force to push down on Tool (A) while the control lever is moved forward to the "FUEL ON" position. Rack travel will stop in the center (zero) position. Hold a light forward force on the governor control lever to keep the fuel racks in the center (zero) position.4. Use Tool (B) to remove bushing (3) from the fuel injection pump housing. 5. Remove bushing (3) and O-ring seal (4).
When injection pumps, spacers and lifters are removed from the injection pump housing, keep the parts of each pump together so they can be installed in their original location.
6. Use Tool (C) to remove fuel injection pump (5). 7. Remove spacer (6) from the fuel injection pump housing. Make a note of the position from which each spacer was removed so each spacer can be installed in its original position.
Be careful when the fuel injection pumps are disassembled. Do not damage the surfaces of the plungers, barrels and bonnets. Any scratches will cause leakage inside the fuel injection pump. The plunger and barrel for each pump are made as a set. Do not put the plunger of one pump in the barrel of another pump. The check assemblies are made as a set. Do not mix the parts of the different check assemblies. Do not remove or make any adjustments of the gear segment on the plunger. It has been preset at the factory. If one part has wear, install a complete new pump assembly. Be careful when the plunger is put into the bore of the barrel.
8. Disassemble the fuel injection pump as follows: Remove ring (7). Separate bonnet (10) from barrel (9). Remove the spring and the check assembly from the bonnet. Remove plunger (8), the washer and spring from barrel (9).Install Fuel Injection Pumps
1. Inspect all parts for wear or damage. The plunger and barrel are serviced only as an assembly. 2. Put clean diesel fuel on plunger (1). Put plunger (1), washer (6) and spring (2) in position on barrel (3).3. Put check valve assembly (7) and spring (8) in bonnet (9). Connect bonnet (9) and barrel (3) together with ring (4). 4. Put spacer (10) into position in the pump housing bore. Be sure the correct spacer is with each pump. 5. Note the location of dowels (11) and (12) in the fuel injection pump housing. These dowels are for alignment of the fuel injection pump. 6. Slot (13) in gear segment (5) must align with dowel (11).7. Groove (14) must engage with dowel (12). 8. Use Tool (A) to put the fuel racks in the center (zero) position. See Remove Fuel Injection Pumps.9. Use Tool