Information injection-pump assembly
BOSCH
F 01G 09U 02H
f01g09u02h
ZEXEL
101493-9111
1014939111
Rating:
Service parts 101493-9111 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-0T301
12.
Open Pre:MPa(Kqf/cm2)
18.6{190}
15.
NOZZLE SET
Cross reference number
BOSCH
F 01G 09U 02H
f01g09u02h
ZEXEL
101493-9111
1014939111
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
12.8
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
70.3
68.7
71.9
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.
9.3
7.5
11.1
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(12.8)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
70.3
69.3
71.3
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.1
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
80
76
84
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1+0.25
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
59.8
55.8
63.8
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
101
85
117
Fixing the lever
*
Timer adjustment
Pump speed
r/min
970--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
920
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
-
Advance angle
deg.
0.6
0.3
0.9
Timer adjustment_04
Pump speed
r/min
1250
Advance angle
deg.
0.6
0.3
0.9
Timer adjustment_05
Pump speed
r/min
1500
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=H36
----------
----------
T1=H36
----------
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=38deg+-3deg
----------
aa=32mm
----------
a=70deg+-5deg b=38deg+-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:
Illustration 31 g00295348
(11) Rotating Group. (15) Shaft.
Install the rotating group (11) .
Position the housing so that the internal end of the shaft (15) is angled downward.
Slide the rotating group (11) over the shaft (15) and into the housing. Ensure that the shoes of the rotating group (11) are seated against the yoke.
Illustration 32 g00295349
(34) Pins
Once the rotating group is installed, turn the rotating group in order to ensure that the three pins (34) are still in the special notches. If the rotating group jams, the pins (34) need to be reinserted into the proper position. The three pins in the rotating group are held in the special notches with a "C" clip retaining ring. The "C" clip applies force against the inside diameter of the rotating group's cylinder block in order to hold the pins in position. See Illustration 32.
Illustration 33 g00295352
(7) Valve Block. (9) Housing Gasket. (35) Large Middle Hole.
Install the housing gasket (9) .
Moderately oil the face of the valve block (7) with clean engine oil. Place the control piston onto the control shaft.
Install the valve block (7) .
Place a finger over the large middle hole (35) in the mounting surface of the valve block (7) in order to create a vacuum. This will hold the control piston in place while you are installing the valve block (7) .
Ensure that the housing gasket (9) is not damaged while you are aligning the valve block (7) to the pins in the pump housing.
Illustration 34 g00295353
(7) Valve Block. (8) Bolts.
Start the bolts (8) in the valve block (7) by hand.
Torque the bolts (8) by alternating from all four sides. Torque the bolts (8) in the corners first. Tighten the bolts (8) to a torque of 27 2 N m (20 1 lb ft).
Illustration 35 g00295295
(5) O-Ring Seals. (6) O-Ring Seals.
Install the four O-Ring seals (5) on the bottom side of the adapter.
Install the four O-Ring seals (6) on the two housings.
Illustration 36 g00295294
(3) Compensator. (4) Bolts.
Install the compensator (3) and the adapter as a unit vertically so that the O-Ring seals are not damaged. Tighten the bolts (4) to a torque of 7.45 .65 N m (65.94 5.75 lb in).
Moderately oil the shaft seal.
Illustration 37 g00295354
(25) Shaft Seal. (36) FT-2608 Bearing Installation Tool .Note: Step 20 through Step 22 defines the procedure for the installation of the shaft seal. These steps should be followed precisely. The shaft seal should be placed barely below the face of the housing. The snap ring should then be positioned against the seal. Both the snap ring and the seal should be driven into the bore together until the snap ring seats in the groove.
Use the FT-2608 Bearing Installation Tool (36) to lower the shaft seal (25) below the edge of the bore.
Place the snap ring against the shaft seal below the edge of the bore.
Illustration 38 g00295356
(25) Shaft Seal. (26) Snap Ring. (36) FT-2608 Bearing Installation Tool .
Use the FT-2608 Bearing Installation Tool (36) in order to lower the shaft seal (25)