108622-3671 ZEXEL F 01G 09U 0FK BOSCH INJECTION-PUMP ASSEMBLY f01g09u0fk 1086223671


 

Information injection-pump assembly

BOSCH F 01G 09U 0FK f01g09u0fk
ZEXEL 108622-3671 1086223671
108622-3671 INJECTION-PUMP ASSEMBLY
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Service parts 108622-3671 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 108062-3420
3. GOVERNOR 105923-2631
4. SUPPLY PUMP 105237-4690
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105664-0890
7. COUPLING PLATE 156638-0820
9. _
10. NOZZLE AND HOLDER ASSY 105101-8261
11. Nozzle and Holder 23600-3060A
12. Open Pre:MPa(Kqf/cm2) 16.7{170}/23.5{240}
13. NOZZLE-HOLDER 105030-3612
14. NOZZLE
15. NOZZLE SET 105019-0930

Include in #1:

108622-3671 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 01G 09U 0FK f01g09u0fk
ZEXEL 108622-3671 1086223671


Zexel num
Bosch num
Firm num
Name
108622-3671 
108622-3672 
F 01G 09U 0FK 
   
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   134424-1420
Overflow valve opening pressure kPa   162 147 177
Overflow valve opening pressure kgf/cm2   1.65 1.5 1.8
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.   31
Direction of rotation (viewed from drive side)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-4-2-6- 3-5
Pre-stroke mm   6.4 6.37 6.43
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   15.1
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   193 190 196
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the rack   *
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   4+-0.05
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   -
Rack position   8.3+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   15 12 18
Max. variation between cylinders %   0 -15 15
Fixing the rack   *
PS407980-224* V   V1+0.05+ -0.01
PS407980-224* mm   6.3+-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(15.1)
Pump speed r/min   500 500 500
Average injection quantity mm3/st.   193 191 195
Basic   *
Fixing the lever   *
Boost pressure kPa   90.6 90.6
Boost pressure mmHg   680 680
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   4+-0.05
Injection quantity adjustment_04
Adjusting point   B
Rack position   (R1+0.65 )
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   207 201 213
Fixing the lever   *
Boost pressure kPa   90.6 90.6
Boost pressure mmHg   680 680
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   4+-0.05
Injection quantity adjustment_05
Adjusting point   D
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   250 245 255
Fixing the lever   *
Boost pressure kPa   90.6 90.6
Boost pressure mmHg   680 680
Rack limit   *
PS407980-224* V   2.45+-0. 01
PS407980-224* mm   4+-0.05
Boost compensator adjustment
Pump speed r/min   300 300 300
Rack position   (R1-3.4)
Boost pressure kPa   6.7 5.4 8
Boost pressure mmHg   50 40 60
Boost compensator adjustment_02
Pump speed r/min   300 300 300
Rack position   R1(15.1)
Boost pressure kPa   77.3 77.3 77.3
Boost pressure mmHg   580 580 580
0000001601
Pre-stroke mm   6.4 6.37 6.43
Remarks
When the timing sleeve is pushed up
 
_02
Connector angle deg.   8.5 8 9
Remarks
When the eccentric pin is tightened
 
_03
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   4 3.95 4.05
Output voltage V   2.45 2.44 2.46
Adjustment   *
_04
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   6.4 6.37 6.43
Output voltage V   1.2 1 1.4
Confirmation   *
Remarks
Output voltage V1
 
_05
Supply voltage V   24 23.5 24.5
Ambient temperature degC   23 18 28
Pre-stroke mm   3.4
Output voltage V   3 2.98 3
Confirmation   *
_06
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

Test data 108622-3671
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=AE75 BCL=(3.4)+-0.1mm
----------

Speed control lever angle

Test data 108622-3671
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=42.5mm
----------
a=35deg+-3deg b=36deg+-5deg

Stop lever angle

Test data 108622-3671
N:Pump normal S:Stop the pump. (1)Pump speed aa, rack position bb (2)Set the stopper screw. (After setting, apply red paint.) (3)Position at the normal side lever position (back off the stop screw and move fully to the normal side). Next, screw in the stop screw and set where it contacts the stop lever. (4)Use the hole above R = cc
----------
aa=0r/min bb=1.5+-0.3mm cc=30mm
----------
a=20deg+-5deg b=45deg+-5deg

0000001301

Test data 108622-3671
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=6.4+-0.03mm
----------
a=(1deg)

0000001901

Test data 108622-3671
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.
----------

----------

0000002201 RACK SENSOR

Test data 108622-3671
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump Adjustment of the rack sensor (-2320) 1. Rack limit adjustment (1)After mounting the joint (B), select the shim (D) so that the rack position is in the rack limit position. (2)Install the rod (e) to the block (c). (3)At the rack limit, set the distance between the pump end face and the rod (E) to L1. 2. Rack sensor (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side and set the pump speed at N1. (3)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (If equipped with a boost compensator, perform with boost pressure applied.) (4)Adjust the bobbin (a) so that the rack sensor output voltage becomes VR +-0.01(V). (5)Apply red paint to both the joint (b) and the nut (f) join, and the joint (b) and the pump join. Output voltage VR +-0.01(V), speed N1 r/min, rack position Ra mm
----------
L=43+-0.1mm N1=1000r/min Ra=(R1(15.1)+0.65)mm
----------




Information:

1. Remove the pickup from the injection line. Check to be sure the pickup and injection line are clean and dry. The inner bore of the pickup that contacts the injection line must be clean and dry. If necessary, clean the inner bore with a soft dry cloth. If the pickup is damp, dry it in an oven at approximately 50°C (122°F) before reinstalling on the fuel injection line.2. Check the fuel injection line on which the pickup was installed. Make sure all paint has been removed from around the line and that clean bare metal is exposed. Use fine emery paper to clean the line if necessary.3. Reinstall the pickup on the fuel injection line. Make sure the thumbscrew is tight and the pickup is not touching anything except the line. Observe the NO INPUT SIGNAL light and the digital readout on the multitach. If the light stays on bright all the time and the digital display reads 0 when the engine is running, the pickup is not operating. Remove the pickup and amplifier, and test the pickup and amplifier as shown on pages 6 and 7, or use a different pickup and amplifier.4. If the pickup is operating but the NO INPUT SIGNAL light and digital readout are erratic, the pickup output signal is either too low or it is noisy. Run the engine at low and high speeds. If the output signal is too low, the pickup will operate better at high engine speeds. If the signal is noisy, the pickup will usually perform better at low engine speeds. To correct either of these problems, loosen the thumbscrew and rotate the pickup to a new position on the line. Tighten the thumbscrew. Check to see if this solves the problem. To correct noisy operation, it may also be necessary to remove the pickup and reverse it 180° so the signal line points in the opposite direction.5. If pickup operation is still erratic after performing the previous steps, move the pickup to a new location on the same line or to a different line. Make sure each new location is properly prepared before installing pickup. To correct noisy operation (erratic signal and high speed readings), try a pickup location as close as possible to a point where the injection line is fastened to the engine.(D) Use Of The Pickup During Wet Conditions
If the pickup becomes wet, it may operate intermittently or not at all. Although the pickup is water resistant, it is not waterproof. Water spray from rain or other sources may cause the pickup to stop producing an output signal. If this happens, the pickup should be removed from the engine and allowed to dry out thoroughly. If necessary, the pickup can be dried in an oven at approximately 50°C (122°F). After drying, the pickup should operate correctly. If it is not possible to keep the pickup dry, use the following procedure. If the pickup must be used during wet conditions, it may be possible

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Group cross 108622-3671 ZEXEL

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Hino 

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