Information injection-pump assembly
BOSCH
F 01G 09U 08T
f01g09u08t
ZEXEL
106673-2991
1066732991
Rating:
Cross reference number
BOSCH
F 01G 09U 08T
f01g09u08t
ZEXEL
106673-2991
1066732991
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131425-0220
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
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
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
1-5-3-6-
2-4
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5
Cal 1-5 deg. 60 59.5 60.5
Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5
Cal 1-3 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5
Cyl.1-2 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5
Cal 1-4 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.9
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
147
143.3
150.7
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
Z
Rack position
8+-0.5
Pump speed
r/min
390
390
390
Each cylinder's injection qty
mm3/st.
15.8
13.4
18.2
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.9)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
147
146
148
Basic
*
Fixing the lever
*
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+1.05
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
143.5
139.5
147.5
Fixing the lever
*
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.75
)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
142
136
148
Fixing the lever
*
Boost pressure
kPa
23.3
23.3
Boost pressure
mmHg
175
175
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
(R2-1.3)
Boost pressure
kPa
4
2.7
5.3
Boost pressure
mmHg
30
20
40
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R2(R1-1)
Boost pressure
kPa
10.7
10.7
10.7
Boost pressure
mmHg
80
80
80
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)Boost compensator stroke: BCL
(4)Damper spring setting
----------
T1=AC25 BCL=(1.3)+-0.1mm
----------
----------
T1=AC25 BCL=(1.3)+-0.1mm
----------
Timer adjustment
(1)Adjusting range
(2)Step response time
(N): Speed of the pump
(L): Load
(theta) Advance angle
(Srd1) Step response time 1
(Srd2) Step response time 2
1. Adjusting conditions for the variable timer
(1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
----------
L=1-0.2mm N2=800r/min C2=(10)deg t1=2.5--sec. t2=2.5--sec.
----------
N1=750++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=10+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
F:Full speed
I:Idle
(1)Use the hole at R = aa
(2)Stopper bolt set position 'H'
(3)Viewed from feed pump side.
----------
aa=37.5mm
----------
a=2deg+-5deg b=39.5deg+-3deg
----------
aa=37.5mm
----------
a=2deg+-5deg b=39.5deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Normal engine position (Rack position corresponding to bb)
(3)Set the stopper bolt so that speed = cc and rack position = dd (and confirm non-injection).
----------
aa=54mm bb=18mm cc=1100r/min dd=3.5+-0.3mm
----------
a=(20.5deg) b=29.5deg+-5deg c=40deg+-5deg
----------
aa=54mm bb=18mm cc=1100r/min dd=3.5+-0.3mm
----------
a=(20.5deg) b=29.5deg+-5deg c=40deg+-5deg
0000001501 RACK SENSOR
(VR) measurement voltage
(I) Part number of the control unit
(G) Apply red paint.
(H): End surface of the pump
1. Rack sensor adjustment (-0620)
(1)Fix the speed control lever at the full position
(2)Set the speed to N1 r/min.
(If the boost compensator is provided, apply boost pressure.)
(3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01.
(4)At that time, rack position must be Ra.
(5)Apply G at two places.
Connecting part between the joint (B) and the nut (F)
Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1100r/min Ra=R1(12.9)+1.05mm
----------
----------
N1=1100r/min Ra=R1(12.9)+1.05mm
----------
0000001601 MICRO SWITCH
Adjustment of the micro-switch
Adjust the bolt to obtain the following lever position when the micro-switch is ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=325r/min Ra=7.6+-0.1mm
----------
----------
N1=325r/min Ra=7.6+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)-
----------
aa=5deg
----------
a=(2deg)
----------
aa=5deg
----------
a=(2deg)
Information:
Governor Linkage Adjustment
(1) Rod. (2) Nut. (3) Control lever. (4) Lever. (5) Pin. (6) High idle stop. (7) Locknut. (8) Low idle stop. (9) Locknut. (10) Decelerator treadle. (11) Floor plate. (12) Accelerator treadle. (13) Lever. (14) Rod. (15) Locknut. (16) Lever. (17) Locknut. (A) 9.7 1.5 mm (.38 .06 in). (B) 4.8 1.5 mm (.19 .06 in). (C) 38.1 1.5 mm (1.50 .06 in). (D) 60.5 3.0 mm (2.38 .12 in).Governor Linkage Adjustment
DO NOT USE control lever (3), or decelerator treadle (10) to shut OFF the engine.To shut engine OFF, pull up on accelerator treadle (12).1. Tighten nut (2) just enough so position of control lever (3) is not affected by the operation of the accelerator treadle (12) and decelerator treadle (10).2. With the parking brake ON and engine stopped, BE SURE disconnect switch is OFF.3. Remove pin (5).4. Loosen LOW IDLE stop (8) and HIGH IDLE stop (6) so they do not touch lever (13).5. Move control lever (3) to LOW IDLE position.6. Turn LOW IDLE stop (8) until it touches lever (13) and tighten locknut (9).7. Adjust length of rod (14) so distance from top of lever (16) to bottom of floor plate (11) is (C) 38.1 1.5 mm (1.50 .06 in) as shown.8. Loosen locknut (15) and adjust length of rod so top of decelerator treadle (10) is (B) 4.8 mm (.19 in) above floor plate (11) as shown. If machine is equipped with a thick floor insulation pad, (used with enclosed cab), adjust decelerator treadle (10) so top of treadle is (A) 9.7 1.5 mm (.38 .06 in) above top of floor plate and tighten locknut (15).9. Move control lever (3) to HIGH IDLE position.10. Turn HIGH IDLE stop (6) until it touches lever (13) and tighten locknut (7).11. Loosen locknut (17) and adjust accelerator treadle (12) so that distance from bottom of plate on treadle to top of floor plate (11) is (D) 60.5 3.0 mm (2.38 .12 in) as shown.12. Move lever (4) to HIGH IDLE position and adjust length of rod (1) so pin (5) can be installed.13. Install pin (5).
DO NOT adjust the linkage so the treadle can be used to shut off the engine. If the operator is in a standing position and places a foot on the treadle, the engine could be unexpectedly shut off, creating a situation where the machine can be difficult to control.
814B, 815B, 816B, 966D
1. Set governor shaft to the off position (approximately 35° right of twelve o'clock) and attach lever (1).2. Adjust cable assembly (2) to within 3 mm (.12 in) of the end of travel and tighten bulkhead (3) nuts to ... 100 15