Information injection-pump assembly
BOSCH
F 01G 09U 0AU
f01g09u0au
ZEXEL
106873-2360
1068732360

Rating:
Service parts 106873-2360 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME091308
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
15.
NOZZLE SET
Include in #1:
106873-2360
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 01G 09U 0AU
f01g09u0au
ZEXEL
106873-2360
1068732360
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
10.6
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
134.6
130.6
138.6
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(10.6)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
134.6
133.6
135.6
Basic
*
Fixing the lever
*
Boost pressure
kPa
28
28
Boost pressure
mmHg
210
210
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.15
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
138.8
134.8
142.8
Fixing the lever
*
Boost pressure
kPa
28
28
Boost pressure
mmHg
210
210
Injection quantity adjustment_05
Adjusting point
D
Rack position
-
Pump speed
r/min
200
200
200
Average injection quantity
mm3/st.
100
60
140
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_06
Adjusting point
E
Rack position
R1+0.35
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
142.8
139.8
145.8
Fixing the lever
*
Boost pressure
kPa
28
28
Boost pressure
mmHg
210
210
Injection quantity adjustment_07
Adjusting point
F
Rack position
R1-0.9
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
116.8
114.8
118.8
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_08
Adjusting point
G
Rack position
12+-0.1
Pump speed
r/min
200
200
200
Average injection quantity
mm3/st.
135
125
145
Fixing the lever
*
Boost pressure
kPa
28
28
Boost pressure
mmHg
210
210
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
450
450
450
Rack position
R1-0.9
Boost pressure
kPa
3.3
3.3
5.3
Boost pressure
mmHg
25
25
40
Boost compensator adjustment_02
Pump speed
r/min
450
450
450
Rack position
R1(10.6)
Boost pressure
kPa
10
8.7
11.3
Boost pressure
mmHg
75
65
85
Boost compensator adjustment_03
Pump speed
r/min
450
450
450
Rack position
(11.4)
Boost pressure
kPa
14.7
14.7
14.7
Boost pressure
mmHg
110
110
110
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.
4.5
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)RACK LIMIT: RAL
(6)Boost compensator stroke
(7)Damper spring setting
(8)Rack difference between N = N1 and N = N2
----------
RT=1 TH=2.1mm BSL=1.4mm RAL=12+-0.1mm N1=990r/min N2=700r/min
----------
----------
RT=1 TH=2.1mm BSL=1.4mm RAL=12+-0.1mm N1=990r/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=5.6+-0.1mm
----------
----------
N1=325r/min Ra=5.6+-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:
This engine may be equipped with a 12 or 24 volt starting system. Use only equal voltage for boost starting. The use of a welder or higher voltage will damage the electrical system.
Charging System Components
Alternator
The alternator is driven by belts from the crankshaft pulley. This alternator is a three phase, self-rectifying charging unit, and the regulator is part of the alternator.The alternator design has no need for slip rings or brushes, and the only part that has movement is the rotor assembly. All conductors that carry current are stationary. The conductors are: the field winding, stator windings, six rectifying diodes, and the regulator circuit components.The rotor assembly has many magnetic poles like fingers with air space between each opposite pole. The poles have residual magnetism (like permanent magnets) that produce a small amount of magnet-like lines of force (magnetic field) between the poles. As the rotor assembly begins to turn between the field winding and the stator windings, a small amount of alternating current (AC) is produced in the stator windings from the small magnetic lines of force made by the residual magnetism of the poles. This AC current is changed to direct current (DC) when it passes through the diodes of the rectifier bridge. Most of this current goes to charge the battery and to supply the low amperage circuit, and the remainder is sent on to the field windings. The DC current flow through the field windings (wires around an iron core) now increases the strength of the magnetic lines of force. These stronger lines of force now increase the amount of AC current produced in the stator windings. The increased speed of the rotor assembly also increases the current and voltage output of the alternator.The voltage regulator is a solid state (transistor, stationary parts) electronic switch. It feels the voltage in the system and switches on and off many times a second to control the field current (DC current to the field windings) for the alternator to make the needed voltage output.
Never operate the alternator without the battery in the circuit. Making or breaking an alternator connection with heavy load on the circuit can cause damage to the regulator.
Alternator Components
(1) Regulator. (2) Roller bearing. (3) Stator winding. (4) Ball bearing. (5) Rectifier bridge. (6) Field winding. (7) Rotor assembly. (8) Fan.Starting System Components
Solenoid
Typical Solenoid SchematicA solenoid is a magnetic switch that does two basic operations.a. Closes the high current starter motor circuit with a low current start switch circuit.b. Engages the starter motor pinion with the ring gear.The solenoid switch is made of an electromagnet (one to two sets of windings) around a hollow cylinder. There is a plunger (core) with a spring load inside the cylinder that can move forward and backward. When the start switch is closed and electricity is sent through the windings, a magnetic field is made that pulls the plunger forward in the cylinder. This moves the shift lever (connected to the rear of the plunger) to engage the pinion