107692-0861 ZEXEL F 01G 09U 0DU BOSCH INJECTION-PUMP ASSEMBLY f01g09u0du 1076920861

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09U 0DU f01g09u0du

ZEXEL 107692-0861 1076920861

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Cross reference number

BOSCH F 01G 09U 0DU f01g09u0du

ZEXEL 107692-0861 1076920861

Zexel num

Bosch num

Firm num

Name

107692-0861
107692-0862

F 01G 09U 0DU

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 131425-0520

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 14

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 5.6 5.57 5.63

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 11.3

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 92.5 90.5 94.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

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 475 475 475

Average injection quantity mm3/st. 10.6 8.8 12.4

Max. variation between cylinders % 0 -10 10

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5.5+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.3)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 92.5 91.5 93.5

Basic *

Fixing the lever *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 5

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_03

CU407980-224* *

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

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.
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T1=AE59
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
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aa=93.5mm
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a=18.5deg+-5deg b=34.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Set the stopper bolt so that rack position = bb (speed = cc)
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aa=37mm bb=3+-0.3mm cc=0r/min
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a=20deg+-5deg b=42deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
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aa=5.6+-0.03mm
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a=(20deg)

0000001401

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
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0000001701

A : Stopper pin B: Connector
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0000001801

C:Shim
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0000001901

A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
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0000002201 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)
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N1=800r/min Ra=R1(11.3)mm
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Information:

Start By:a. remove crankshaft vibration damper and pulley
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
When replacement of the front seal is made, a replacement of the wear sleeve must also be made.
1. Remove the two bolts, washers, clamp (1), retainer (2) and the O-ring seal.2. Use tool (A) and a press to remove seal (3).3. Install the O-ring seal, retainer (2) and the two bolts, washers, and clamp (1). 4. Install tool (C) in the bore of retainer (2) as shown.5. Install tool (B) between tool (C) and the wear sleeve. Turn tool (B) with a wrench until the edge of the tool makes a flat place (crease) in the wear sleeve. Do this in two or more places until the wear sleeve is loose.6. Remove tool (C) and the wear sleeve by hand.Install Crankshaft Front Seal And Wear Sleeve
1. Install crankshaft front seal (1) and wear sleeve (2) with tool (A) as follows:a. Put clean engine oil on the seal lip of seal (1) and on the outside diameter of wear sleeve (2). Install seal (1) on wear sleeve (2) as shown.b. Use 6V1541 Quick Cure Primer to clean the outside diameter of crankshaft (3) and the inside diameter of wear sleeve (2).c. Put 9S3265 Retaining Compound on the outside diameter of crankshaft (3) and the inside diameter of wear sleeve (2). Make sure the lip of the seal is toward the engine and the outside diameter bevel of the wear sleeve is toward the outside of the engine.d. Put wear sleeve (2) with seal (1) on the front of the crankshaft as shown in illustration B20159P1. Install tool (A). Tighten the bolt in tool (A) until the inside surface of the installer in tooling (A) makes contact with the end of the crankshaft.End By:a. install crankshaft vibration damper and pulley