Information injection-pump assembly
BOSCH
F 01G 09U 0AT
f01g09u0at
ZEXEL
106873-2330
1068732330
Rating:
Cross reference number
BOSCH
F 01G 09U 0AT
f01g09u0at
ZEXEL
106873-2330
1068732330
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
Overflow valve
131424-4620
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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
1-2-7-3-
4-5-6-8
Pre-stroke
mm
4.8
4.75
4.85
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cyl.1-2 deg. 45 44.5 45.5
Cyl.1-2 deg. 45 44.5 45.5
Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5
Cal 1-7 deg. 90 89.5 90.5
Difference between angles 3
Cal 1-3 deg. 135 134.5 135.5
Cal 1-3 deg. 135 134.5 135.5
Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 5
Cal 1-5 deg. 225 224.5 225.5
Cal 1-5 deg. 225 224.5 225.5
Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5
Cal 1-6 deg. 270 269.5 270.5
Difference between angles 7
Cal 1-8 deg. 315 314.5 315.5
Cal 1-8 deg. 315 314.5 315.5
Injection quantity adjustment
Adjusting point
-
Rack position
11.2
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
148.5
144
153
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
5.9+-0.5
Pump speed
r/min
225
225
225
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(11.2)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
148.5
147.5
149.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.05
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
157.8
153.8
161.8
Fixing the lever
*
Boost pressure
kPa
26.7
26.7
Boost pressure
mmHg
200
200
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
R1-1.25
Boost pressure
kPa
3.3
3.3
5.3
Boost pressure
mmHg
25
25
40
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
R1-0.7
Boost pressure
kPa
8
6.7
9.3
Boost pressure
mmHg
60
50
70
Boost compensator adjustment_03
Pump speed
r/min
650
650
650
Rack position
R1(11.2)
Boost pressure
kPa
13.3
6.6
20
Boost pressure
mmHg
100
50
150
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.
0.5
Timer adjustment_03
Pump speed
r/min
1100
Advance angle
deg.
4
3.5
4.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Lever ratio: RT
(2)Target shim dimension: TH
(3)Tolerance for racks not indicated: +-0.05mm.
(4)Boost compensator cancel stroke: BSL
(5)Boost compensator stroke
(6)Damper spring setting
(7)Rack difference between N = N1 and N = N2
----------
RT=1 TH=2.3mm BSL=1.6mm N1=1020r/min N2=700r/min
----------
----------
RT=1 TH=2.3mm BSL=1.6mm N1=1020r/min N2=700r/min
----------
Speed control lever angle
F:Full speed
----------
----------
a=16deg+-5deg
----------
----------
a=16deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=10deg+-5deg b=29.5deg+-3deg
----------
----------
a=10deg+-5deg b=29.5deg+-3deg
Stop lever angle
S:Stop the pump.
(1)Rack position = aa (non-injection rack position)
(2)Stopper bolt setting
(3)Free (at delivery)
----------
aa=3.3-0.5mm
----------
a=10.5deg+-5deg b=58deg+7deg-5deg
----------
aa=3.3-0.5mm
----------
a=10.5deg+-5deg b=58deg+7deg-5deg
0000001501 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=5.4+-0.1mm
----------
----------
N1=325r/min Ra=5.4+-0.1mm
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(40deg)
----------
----------
a=(40deg)
Information:
Do not bend or add stress to the shaft when nut is loosened or tightened.
d. Remove nut from shaft and apply 6V1541 Quick Cure Primer on the threads of the shaft and nut followed by application of 9S3263 Retaining Compound.e. Tighten nut to 4 N m (30 lb in).f. Tighten nut more 90° rotation.(6) Thickness of each thrust ring ... 2.553 0.013 mm (.1005 .0005 in)(7) Bore in housing (new) ... 24.994 to 25.006 mm (.9840 to .9845 in) Outside diameter of the bearing (new) ... 24.882 to 24.892 mm (.9796 to .9800 in)Maximum permissible clearance between bearing and bore in housing (worn) ... 0.15 mm (.006 in)Tighten both band clamps (that hold the compressor and turbine housings to the cartridge group) with procedure that follows: a. Tighten to ... 14 1.1 N m (125 10 lb in)b. Tap (hit) clamp lightly all around.c. Tighten again to ... 14 1.1 N m (125 10 lb in)
Do not overtighten the clamps.
Torque for four nuts (put 5P3931 Anti-Seize Compound on threads) and bolts that hold turbocharger to exhaust manifold ... 55 5 N m (40