106971-5180 ZEXEL F 01G 09U 0C9 BOSCH INJECTION-PUMP ASSEMBLY f01g09u0c9 1069715180

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09U 0C9 f01g09u0c9

ZEXEL 106971-5180 1069715180

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Service parts 106971-5180 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106097-5760

3. GOVERNOR 105952-2151

4. SUPPLY PUMP 105237-4210

5. AUTOM. ADVANCE MECHANIS 105683-0720

6. COUPLING PLATE 105663-0570

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-7651

11. Nozzle and Holder 16600-97160

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/22.6{230}

13. NOZZLE-HOLDER 105041-3150

14. NOZZLE

15. NOZZLE SET 105019-0591

Include in #1:

106971-5180 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 01G 09U 0C9 f01g09u0c9

ZEXEL 106971-5180 1069715180

Zexel num

Bosch num

Firm num

Name

106971-5180
106971-5181

F 01G 09U 0C9

INJECTION-PUMP ASSEMBLY
* K

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 10-9 deg. 45 44.75 45.25

Difference between angles 2
Cal 10-4 deg. 72 71.75 72.25

Difference between angles 3
Cal 10-3 deg. 117 116.75 117.25

Difference between angles 4
Cal 10-6 deg. 144 143.75 144.25

Difference between angles 5
Cal 10-5 deg. 189 188.75 189.25

Difference between angles 6
Cal 10-8 deg. 216 215.75 216.25

Difference between angles 7
Cal 10-7 deg. 261 260.75 261.25

Difference between angles 8
Cal 10-2 deg. 288 287.75 288.25

Difference between angles 9
Cal 10-1 deg. 333 332.75 333.25

Injection quantity adjustment

Rack position (12.6)

Vist V 1.96 1.96 1.96

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 114 112 116

Max. variation between cylinders % 0 -4 4

Basic *

Injection quantity adjustment_02

Rack position (8.6)

Vist V 2.6 2.5 2.7

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 16 14 18

Max. variation between cylinders % 0 -10 10

Governor adjustment

Pump speed r/min 770--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 720

Advance angle deg. 0.3

Governor adjustment_03

Pump speed r/min (850)

Advance angle deg. 2 1.7 2.3

Governor adjustment_04

Pump speed r/min 1000

Advance angle deg. 3.2 3.2 3.2

Governor adjustment_05

Pump speed r/min 1090

Advance angle deg. 7 6.7 7.3

Remarks
Finish

Test data Ex:

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

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)

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:

2. Loosen clamp (1).3. Remove two bolts (2).4. Remove two bolts (3) and washers.5. Remove water pump (4) and the gasket. When installing replace the gasket. Make sure all gasket surfaces are clean and free of dirt. For installation of the water pump, reverse the removal steps.6. Fill the radiator with coolant to the proper level. See the Operation & Maintenance Manual.Disassemble & Assemble Water Pump
The following tools are needed for disassembly. Start By:a. remove water pump 1. Remove bolt (15) and the washer. Remove bearing (12) and gear (10) as a unit.2. Use Tool (A), (C) and a press, and remove bearing (12) from gear (10).3. Remove snap ring (8) with Tool (B).4. Remove two bolts (1), the washers, cover (14) and gasket (2) from water pump housing (18).5. Loosen bolt (13) approximately 6.4 mm (.25 in). Hit the bolt with a soft hammer to loosen impeller (16) from shaft (9).6. Remove bolt (13), washer (11), impeller (16), spring (3) and seal assembly (4) from shaft (9).7. Remove bearing (7) and shaft (9) as a unit.8. Use Tool (A), (C) and a press to remove bearing (7) from shaft (9).9. Remove ceramic seal (5) and seal (17) from water pump housing (18).10. Use Tool (C) to remove lip-type seal (6) from the water pump housing. The following steps are for assembly of the water pump. The following tools are needed for assembly. 11. Install lip-type seal (6) in water pump housing (18) with Tool (C). The lip of the seal must be toward the bearings. Put clean engine oil on the lip of the seal.12. Install shaft (9) in bearing (7) with a press.13. Install shaft (9) and bearing (7) as a unit in water pump housing (18).14. Install snap ring (8) with Tool (B).
Clean water only is permitted for use as a lubricant for assembly. Do not damage or put hands on the wear surface of the carbon ring or the ceramic ring. Install the ceramic ring with the smoothest face of the ring toward the carbon seal assembly.
15. Put ceramic ring (5) in position in seal (17). Use hand pressure and Tool (D) to install the ceramic ring.16. Remove spring (3) from seal assembly (4). Use hand pressure and Tool (D) to install the seal assembly. Push seal assembly (4) on shaft (9) until it makes light contact with ceramic ring (5).17. Install spring (3) on seal assembly (4). Put impeller (16) in position on shaft (9), and install washer (11) and bolt (13) that hold it. Tighten bolt (13) to a torque of 38.0 1.5 N m (28 1 lb ft).18. Put gasket (2) and cover (14) in position on water pump housing (18). Install the two washers and bolts (1) that hold them.19. Install bearing (12) on gear (10) with a press.20. Position gear (10) and bearing (12) as a unit on shaft (9). Install the washer and bolt (15) that hold them together. Tighten bolt (15) to a torque of