Information injection-pump assembly
BOSCH
F 01G 09U 0BF
f01g09u0bf
ZEXEL
106873-7620
1068737620
Rating:
Service parts 106873-7620 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
ME161933
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/24.5{250}
14.
NOZZLE
Include in #1:
106873-7620
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 01G 09U 0BF
f01g09u0bf
ZEXEL
106873-7620
1068737620
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
1-2-7-3-
4-5-6-8
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
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
12.6
Pump speed
r/min
700
700
700
Each cylinder's injection qty
mm3/st.
142
137.7
146.3
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
445
445
445
Each cylinder's injection qty
mm3/st.
16.5
14
19
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.6)
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
142
141
143
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.85
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
138
134
142
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
(R1-0.8)
Pump speed
r/min
500
500
500
Average injection quantity
mm3/st.
138
134
142
Fixing the lever
*
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)Damper spring setting
----------
T1=AD95
----------
----------
T1=AD95
----------
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=30deg+-5deg b=35deg+-3deg
----------
aa=37.5mm
----------
a=30deg+-5deg b=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper bolt so that speed = bb and rack position = cc. (Confirm non-injection.)
(3)Normal engine position (Rack position corresponding to dd)
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)
----------
aa=54mm bb=1100r/min cc=3.5+-0.3mm dd=18mm
----------
a=41deg+-5deg b=5.5deg+-5deg c=(31deg)
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(12.6)+0.85mm
----------
----------
N1=1100r/min Ra=R1(12.6)+0.85mm
----------
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=6deg
----------
a=(50deg)
----------
aa=6deg
----------
a=(50deg)
Information:
Connect the wiring harness to a voltage source of 12 VOLTS maximum with a negative ground only. Install the additive tank on the outside of the engine compartment.
Connect the wiring to 8L5000 Switch (1) so that the system can be activated with the starting motor switch in the OFF position. Keep the additive tank full when not in use. This will prevent damage to the system and components by corrosion when not used for long periods of time.Operation: Just before the engine is started, push the switch to activate the system; this will let the additive flow for approximately two minutes, through an orifice connected to the fuel supply line of the Sleeve Metering Fuel System. The fuel transfer pump then pulls the additive into the system along with the Diesel fuel. The system can be again activated if necessary. The engine can be started approximately three to four times per liter (fifteen to twenty times per gallon) of additive.Maintenance: Keep the additive tank full when not in use. This will prevent damage to the system and components by corrosion when not used for long periods of time. Install a new injection group filter (9N3778) at six month intervals or when the filter becomes plugged (full of foreign material) so additive will not flow through it. ADDITIVE RECOMMENDATION: Ethyl D112 Diesel Ignition Improver AVAILABLE SOURCE:U.S.A.
Ethyl Corporation
Distribution Service
Petroleum Chemical Division
451 Florida Boulevard
Baton Rouge, Lousiana 70801
CANADA
Ethyl Corporation of Canada, Ltd.
48 St. Clair Avenue West
Toronto, Ontario, Canada M4V1M7
Order Department
Ethyl D11-2 Diesel Ignition Improver is highly flammable; do not install the additive tank near a source of heat or sparks. If there is a leak in the tank or an accident causes a loss of additive, a fire could be the result.
1 - 9N3334 Tank Assembly2 - 1P4022 Fitting3 - 9N3778 Filter Assembly4 - 8L6557 Connector5 - 317224 Hose Assembly6 - 306984 Connector7 - 9L8791 Solenoid8 - 7W1539 Orifice9 - 8T2543 Tee10 - 5P5009 Reducer11 - 9N3828 Harness Assembly12 - 7G1018 Relay13 - 8L5000 Switch14 - 9N3335 Strap 533567 Bracket15 - 5P0733 Hose 200 (8.0")16 - 1P4278 Clamp17 - 7D1553 Clip18 - 8J1256 Clip19 - 4B1248 Screw 4B2051 Nut 4B4674 Washer20 - 3J7354 Seal21 - 1J9671 Seal1 Install items (12) and (13) inside the operator's compartment; fasten switch (13) on the dash and install relay (12) under the dash. Install additive tank (1) on the outside of the engine compartment in an acceptable location for easy access and away from any source of heat.2 Install 9N3620 Fuel Additive Injection Instruction Film on the dash next to 8L5000 Switch (13). Install 9N3621 CAUTION Film on tank (1) at a location that can be seen from the side of the vehicle.3 Install the remainder of the parts as shown in the above illustration. Fasten filter (3), and hoses (5) and (15) with the clips shown.4 Check the system for leaks after the installation is complete; use air at a maximum pressure of 70 to 105 kPa (10 to 15 psi).