Information injection-pump assembly
BOSCH
F 01G 09U 0C7
f01g09u0c7
ZEXEL
106971-5105
1069715105
Rating:
Cross reference number
BOSCH
F 01G 09U 0C7
f01g09u0c7
ZEXEL
106971-5105
1069715105
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
131425-0120
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
RED3 control unit part number
407910-3
960
RED3 rack sensor specifications
mm
19
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
10-9-4-3
-6-5-8-7
-2-1
Pre-stroke
mm
4.4
4.37
4.43
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 10-9 deg. 45 44.75 45.25
Cal 10-9 deg. 45 44.75 45.25
Difference between angles 2
Cal 10-4 deg. 72 71.75 72.25
Cal 10-4 deg. 72 71.75 72.25
Difference between angles 3
Cal 10-3 deg. 117 116.75 117.25
Cal 10-3 deg. 117 116.75 117.25
Difference between angles 4
Cal 10-6 deg. 144 143.75 144.25
Cal 10-6 deg. 144 143.75 144.25
Difference between angles 5
Cal 10-5 deg. 189 188.75 189.25
Cal 10-5 deg. 189 188.75 189.25
Difference between angles 6
Cal 10-8 deg. 216 215.75 216.25
Cal 10-8 deg. 216 215.75 216.25
Difference between angles 7
Cal 10-7 deg. 261 260.75 261.25
Cal 10-7 deg. 261 260.75 261.25
Difference between angles 8
Cal 10-2 deg. 288 287.75 288.25
Cal 10-2 deg. 288 287.75 288.25
Difference between angles 9
Cal 10-1 deg. 333 332.75 333.25
Cal 10-1 deg. 333 332.75 333.25
Injection quantity adjustment
Rack position
(13.4)
Vist
V
1.84
1.84
1.84
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
128.5
126.5
130.5
Max. variation between cylinders
%
0
-4
4
Basic
*
Injection quantity adjustment_02
Rack position
(8.8)
Vist
V
2.5
2.4
2.6
Pump speed
r/min
370
370
370
Average injection quantity
mm3/st.
16
14
18
Max. variation between cylinders
%
0
-10
10
Test data Ex:
Governor 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.
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L=1-0.2mm N2=800r/min C2=(9)deg t1=1.7--sec. t2=1.7--sec.
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N1=1000++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=9+-0.3deg R01=0/4load R02=4/4load
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L=1-0.2mm N2=800r/min C2=(9)deg t1=1.7--sec. t2=1.7--sec.
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N1=1000++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=9+-0.3deg R01=0/4load R02=4/4load
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
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aa=20mm bb=1mm
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a=27deg+-5deg b=37deg+-5deg
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aa=20mm bb=1mm
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a=27deg+-5deg b=37deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of the coupling's key groove at the start of injection for the No. 10 cylinder.
(3)-
(4)-
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a=(90deg)
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a=(90deg)
Stop lever angle
(Rs) rack sensor specifications
(C/U) control unit part number
(V) Rack sensor output voltage
(R) Rack position (mm)
1. Confirming governor output characteristics (rack 19 mm, span 6 mm)
(1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:
Start By:a. remove turbocharger 1. Install the turbocharger on Tool (A).2. Put alignment marks on the two housings and cartridge assembly of the turbocharger for correct alignment during assembly.3. Loosen clamp (3), and remove compressor housing (4) from cartridge assembly (2).4. Loosen the remaining clamp, and remove cartridge assembly (2) from turbine housing (1).
Typical Example5. Put the cartridge group (shown in the illustration) with nut (16) up in Tool (B). Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (16) that holds the compressor wheel (15) to the wheel assembly (19).6. Remove compressor wheel (15) and housing assembly (6) from wheel assembly (19). Remove piston ring (13) from the wheel assembly.7. Use Tool (C), and remove snap ring (5) from housing assembly (6). Remove insert (14) and sleeve (18) from the housing assembly. Remove seal (22) from insert (14). Remove ring (20) from sleeve (18).8. Remove oil deflector (23), thrust ring (21), bearing assembly (7), spacer sleeve (24) and thrust ring (8) from housing assembly (6).9. Use Tool (D), and remove snap ring (9) from the housing assembly. Remove bearing (25). Remove snap ring (10) with Tool (D).10. Use Tool (D), and remove snap ring (12) from the housing assembly. Remove bearing (26). Remove snap ring (11) with Tool (D).11. Check all the parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 for turbocharger reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for assembly of the turbocharger.12. Make sure that all the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, put clean engine oil into the oil inlet of the turbocharger.
Make sure the snap rings that hold bearings (25) and (26) in housing assembly (6) are installed with the round edge of the outside diameter toward the bearing.
13. Install snap ring (11) with Tool (D). Install bearing (26). Install snap ring (12) with Tool (D).14. Install snap ring (10) with Tool (D). Install bearing (25). Install snap ring (9) with Tool (D).15. Put wheel assembly (19) in position on Tool (B) with the threaded portion end up. Put 6V2055 High Vacuum Grease in the groove for piston ring (13) at assembly to one half or more of the depth of the groove all the way around.16. Install piston ring (13) in the groove in wheel assembly (19).17. Put housing assembly (6) in position on wheel assembly (19).18. Install thrust ring (8) and spacer sleeve (24) on wheel assembly (19).19. Make sure the screen is in place in bearing assembly (7). Install bearing assembly (7) over spacer sleeve (24). Make sure the screen in the bearing assembly is facing toward housing assembly (6) when it is installed.20. Install thrust ring (21) and oil deflector (23)
Typical Example5. Put the cartridge group (shown in the illustration) with nut (16) up in Tool (B). Use a 5S9566 Sliding T-Wrench and a universal socket to remove nut (16) that holds the compressor wheel (15) to the wheel assembly (19).6. Remove compressor wheel (15) and housing assembly (6) from wheel assembly (19). Remove piston ring (13) from the wheel assembly.7. Use Tool (C), and remove snap ring (5) from housing assembly (6). Remove insert (14) and sleeve (18) from the housing assembly. Remove seal (22) from insert (14). Remove ring (20) from sleeve (18).8. Remove oil deflector (23), thrust ring (21), bearing assembly (7), spacer sleeve (24) and thrust ring (8) from housing assembly (6).9. Use Tool (D), and remove snap ring (9) from the housing assembly. Remove bearing (25). Remove snap ring (10) with Tool (D).10. Use Tool (D), and remove snap ring (12) from the housing assembly. Remove bearing (26). Remove snap ring (11) with Tool (D).11. Check all the parts of the turbocharger for damage. If any parts are damaged, use new parts for replacement. See Special Instruction Form No. SMHS6854 for turbocharger reconditioning. Also, see Guidelines For Reusable Parts, Form No. SEBF8018. The following steps are for assembly of the turbocharger.12. Make sure that all the oil passages in the turbocharger cartridge housing are clean and free of dirt and foreign material. Do not put oil on any parts of the turbocharger until after the compressor wheel has been installed. After the turbocharger has been assembled, put clean engine oil into the oil inlet of the turbocharger.
Make sure the snap rings that hold bearings (25) and (26) in housing assembly (6) are installed with the round edge of the outside diameter toward the bearing.
13. Install snap ring (11) with Tool (D). Install bearing (26). Install snap ring (12) with Tool (D).14. Install snap ring (10) with Tool (D). Install bearing (25). Install snap ring (9) with Tool (D).15. Put wheel assembly (19) in position on Tool (B) with the threaded portion end up. Put 6V2055 High Vacuum Grease in the groove for piston ring (13) at assembly to one half or more of the depth of the groove all the way around.16. Install piston ring (13) in the groove in wheel assembly (19).17. Put housing assembly (6) in position on wheel assembly (19).18. Install thrust ring (8) and spacer sleeve (24) on wheel assembly (19).19. Make sure the screen is in place in bearing assembly (7). Install bearing assembly (7) over spacer sleeve (24). Make sure the screen in the bearing assembly is facing toward housing assembly (6) when it is installed.20. Install thrust ring (21) and oil deflector (23)