Information injection-pump assembly
BOSCH
F 01G 09U 01Z
f01g09u01z
ZEXEL
101491-9963
1014919963
Rating:
Service parts 101491-9963 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-0T003
12.
Open Pre:MPa(Kqf/cm2)
18.6{190}
15.
NOZZLE SET
Cross reference number
BOSCH
F 01G 09U 01Z
f01g09u01z
ZEXEL
101491-9963
1014919963
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
131424-1520
Overflow valve opening pressure
kPa
157
123
191
Overflow valve opening pressure
kgf/cm2
1.6
1.25
1.95
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)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
3.2
3.15
3.25
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.7
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
74
72.4
75.6
Max. variation between cylinders
%
0
-2.5
2.5
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
300
300
300
Average injection quantity
mm3/st.
9.6
7.8
11.4
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.7)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
74
73
75
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.2
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
80.9
76.9
84.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
100
84
116
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1010--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
960
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
(1000)
Advance angle
deg.
0.8
0.5
1.1
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1330+30-
20
Advance angle
deg.
0.8
0.5
1.1
Timer adjustment_05
Pump speed
r/min
1500
Advance angle
deg.
3.45
3.45
3.45
Timer adjustment_06
Pump speed
r/min
1600
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)Tolerance for racks not indicated: +-0.05mm.
----------
T1=G84
----------
----------
T1=G84
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=70deg+-5deg b=37deg+-3deg
----------
aa=32mm
----------
a=70deg+-5deg b=37deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the pin at R = aa
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole (position of gear mark 'S') at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=12deg
----------
a=(60deg)
----------
aa=12deg
----------
a=(60deg)
Information:
Test Points (Voltages And Waveforms)
dc Voltages Conditions: 1. dc input voltage applied to POWER connector as shown.2. CALIBRATION CHECK/OPERATE switch in the OPERATE position.3. Neither transducer connected to indicator.4. TPI is reference for all voltages.Equipment Required: 6V3030 Digital Multimeterdc Input Voltages Waveforms Conditions: 1. dc power input voltage of 25 1 Volts.2. CALIBRATION CHECK/OPERATE switch in the CHECK position (can be held in CHECK position with tape).3. Neither transducer connected to indicator.4. TPI is reference for all waveforms.Equipment Required: dc oscilloscope (dual channel preferred). Waveform Time Relationships
VOLTAGES MAY VARY 10%, PULSE DURATIONS BY 20% EXCEPT 2.66 ms WHICH IS BASED ON A 12.000 kHz OSCILLATOR FREQ. (1C202). SIGNAL SOURCE IS INTERNAL CALIBRATOR. ALL TEST POINTS REFERENCED TO TP1.Waveform Time Relationships (enlarged scale)
VOLTAGES MAY VARY 10%, PULSE DURATIONS BY 20% EXCEPT 83.3 ?s AND 2.66 ms WHICH ARE EXACT BASED ON A 12.000 kHZ OSCILLATOR. (1C202) SIGNAL SOURCE IS INTERNAL CALIBRATOR. ALL TEST POINTS REFERENCED TO TP1.Disassembly Procedure
1 Remove six screws (1) from front panel (2), and remove panel (2) from case (3). Remove four screws (4) from the PC board, and also remove the locknuts from the two front panel switches (5) and (6). Carefully lift front panel (2) from PC (printed circuit) board (7).Calibration Procedure
To make sure the 6V3100 Timing Indicator Group (1) has good accuracy, check its calibration at a minimum of every six months. Also, the timing indicator will need calibration if: A. It does not show 2000 30 R/MIN at (A) and 32.0 .2 DEG at (B), when the CALIBRATION CHECK-OPERATE Switch (C) is in the CALIBRATION CHECK position. With no input signal at (D) or (E), the reading at R/MIN location (A) must show three zeros (000). If four zeros (0000) show, it is an indication of a possible need for calibration of the unit. This error only is not reason enough to do a complete calibration procedure. It is also not necessary to do a complete calibration procedure if the reading at the DEG location (B) has a decimal point as shown, (00.0) in addition to the three zeros.B. Reading is different than (000) at either location (A) or (B).All calibrations can be done with the use of a small screwdriver, a frequency counter and
dc Voltages Conditions: 1. dc input voltage applied to POWER connector as shown.2. CALIBRATION CHECK/OPERATE switch in the OPERATE position.3. Neither transducer connected to indicator.4. TPI is reference for all voltages.Equipment Required: 6V3030 Digital Multimeterdc Input Voltages Waveforms Conditions: 1. dc power input voltage of 25 1 Volts.2. CALIBRATION CHECK/OPERATE switch in the CHECK position (can be held in CHECK position with tape).3. Neither transducer connected to indicator.4. TPI is reference for all waveforms.Equipment Required: dc oscilloscope (dual channel preferred). Waveform Time Relationships
VOLTAGES MAY VARY 10%, PULSE DURATIONS BY 20% EXCEPT 2.66 ms WHICH IS BASED ON A 12.000 kHz OSCILLATOR FREQ. (1C202). SIGNAL SOURCE IS INTERNAL CALIBRATOR. ALL TEST POINTS REFERENCED TO TP1.Waveform Time Relationships (enlarged scale)
VOLTAGES MAY VARY 10%, PULSE DURATIONS BY 20% EXCEPT 83.3 ?s AND 2.66 ms WHICH ARE EXACT BASED ON A 12.000 kHZ OSCILLATOR. (1C202) SIGNAL SOURCE IS INTERNAL CALIBRATOR. ALL TEST POINTS REFERENCED TO TP1.Disassembly Procedure
1 Remove six screws (1) from front panel (2), and remove panel (2) from case (3). Remove four screws (4) from the PC board, and also remove the locknuts from the two front panel switches (5) and (6). Carefully lift front panel (2) from PC (printed circuit) board (7).Calibration Procedure
To make sure the 6V3100 Timing Indicator Group (1) has good accuracy, check its calibration at a minimum of every six months. Also, the timing indicator will need calibration if: A. It does not show 2000 30 R/MIN at (A) and 32.0 .2 DEG at (B), when the CALIBRATION CHECK-OPERATE Switch (C) is in the CALIBRATION CHECK position. With no input signal at (D) or (E), the reading at R/MIN location (A) must show three zeros (000). If four zeros (0000) show, it is an indication of a possible need for calibration of the unit. This error only is not reason enough to do a complete calibration procedure. It is also not necessary to do a complete calibration procedure if the reading at the DEG location (B) has a decimal point as shown, (00.0) in addition to the three zeros.B. Reading is different than (000) at either location (A) or (B).All calibrations can be done with the use of a small screwdriver, a frequency counter and