Information injection-pump assembly
BOSCH
F 01G 09U 03F
f01g09u03f
ZEXEL
101603-2011
1016032011
HINO
220008061A
220008061a
Rating:
Service parts 101603-2011 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2360A
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
BOSCH
F 01G 09U 03F
f01g09u03f
ZEXEL
101603-2011
1016032011
HINO
220008061A
220008061a
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
131424-8320
Overflow valve opening pressure
kPa
108
88
128
Overflow valve opening pressure
kgf/cm2
1.1
0.9
1.3
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
1-4-2-6-
3-5
Pre-stroke
mm
3.8
3.77
3.83
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
11.5
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
78.5
76.9
80.1
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9+-0.5
Pump speed
r/min
250
250
250
Each cylinder's injection qty
mm3/st.
15
14
16
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.5)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
78.5
77.5
79.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.5
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
90.5
86.5
94.5
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.3
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
66.5
62.5
70.5
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.5
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
88
84
92
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
140
150
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
2.5
2.2
2.8
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.
(3)RACK LIMIT
----------
T1=F03
----------
----------
T1=F03
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=57mm
----------
a=40deg+-3deg b=44deg+-5deg
----------
aa=57mm
----------
a=40deg+-3deg b=44deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg
0000001501 TAMPER PROOF
1. Method for setting tamperproof proofing
(1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to Ra.
(2)At pump speed N1, push in the screw (A) until the rack position is Rb.
(3)Temporarily caulk using the tip of a screwdriver
(4)Confirm that the rack at that time is at Rc.
(5)Lock using setscrew (B). (Tightening torque = T)
(6)Next, coat (C) with adhesive and then pressfit.
(7)Then, readjust the full rack position using the load lever.
----------
N1=850r/min Ra=R1+0.65mm Rb=R1+0.65mm Rb=R1+0.65mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)
----------
N1=850r/min Ra=R1+0.65mm Rb=R1+0.65mm Rb=R1+0.65mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Illustration 15: (A) Injector sleeve. (3) Lower pilot. (36) Pipe or tubing.6. Place new injector sleeve (A) into its bore in the cylinder head. Wipe away any excess retaining compound that is either in or above the injector sleeve.7. Install lower pilot (3) into the injector sleeve. To avoid damage to the guide on the lower pilot (3), use a piece of pipe or tubing (36) with a small hammer to LIGHTLY tap the lower pilot. This will ensure that the new injector sleeve is fully seated in the cylinder head.Remove lower pilot (3).
Illustration 16: (14) Roller expander. (32) Mandrel.8. Place a coating of clean engine oil on 4C-6730 Roller Expander (14). Ensure the rollers are completely covered with oil.9. Pull and hold mandrel (32) out of the roller expander (14) as far as possible. Then completely insert the roller expander into the injector sleeve.10. Place a torque wrench with a 11 mm socket on the hex portion of 4C-6730 Roller Expander mandrel. Turn the torque wrench in a clockwise (CW) direction in order to achieve a torque of 11 N m (100 lb in). If torque stops increasing before 11 N m (100 lb in) the sleeve is not hard enough or the bore is oversized in the head.
To ensure that accurate torque is achieved, a calibrated 4C-6936 Torque Wrench or equivalent is required.
11. When the specified torque is reached, stop turning the roller expander in the clockwise (CW) direction. Now turn the roller expander in the counterclockwise (CCW) direction until it is loose in the injector sleeve.Remove 4C-6730 Roller Expander from the injector sleeve.12. Wipe the roller expander, especially the rollers, to remove any traces of 7M-7456 Bearing Mount or Loctite® 609 that may have built up from the injector sleeve. When usage of 4C-6730 Roller Expander is completed, clean it thoroughly using either 1U-8803 Cleaner Concentrate or 8T-9011 Component Cleaner. After the cleaning, place a generous coat of either 1U-8265 Penetrating Oil or 1U-8809 Rust Preventive on the roller expander. Place it in its storage case.
Illustration 17: (A) Injector sleeve. (13) Driver. (15) Guide bushing. Wage/flaring assembly: (8) Set screw. (9) Bottom swage. (11) Flare tool.13. Install 4C-6591 Bottom Swage (9) in 9U-6856 Flare Tool (11) using 4C-5502 Set Screw (8).14. Slide same guide bushing (15) used previously onto 9U-6856 Flare Tool (11).
Some 9U-6856 Flare Tools have their part number stamped on the turn which fits into the guide bushing. This arrangement interferes with the fit. Before the first tool use, the part number should be filed down as necessary in order to permit fit of the flare tool in the guide bushing.
15. Use 5P-3931 Anti-seize Compound, 6V-4876 Molykote Paste Lubricant, or grease to lubricate the swage/flaring assembly. Place it into the sleeve with the flare tool prying notch facing either opening between the valve springs. This will allow access for removal of the swage/flaring assembly.16. Place 9U-6857 Driver (13) on 9U-6856 Flare Tool (11).17. Use a hammer to drive down the swage/flaring assembly until