Information injection-pump assembly
BOSCH
F 01G 09U 0G6
f01g09u0g6
ZEXEL
108821-0020
1088210020
Rating:
Service parts 108821-0020 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
16600-97161
12.
Open Pre:MPa(Kqf/cm2)
15.7{160}/22.6{230}
14.
NOZZLE
Include in #1:
108821-0020
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 01G 09U 0G6
f01g09u0g6
ZEXEL
108821-0020
1088210020
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
134424-4120
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
RED3 control unit part number
407910-3
960
RED3 rack sensor specifications
mm
19
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
42
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
1-8-7-5-
4-3-6-2
Pre-stroke
mm
6.4
6.37
6.43
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-5 deg. 135 134.75 135.25
Cal 1-5 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-3 deg. 225 224.75 225.25
Cal 1-3 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25
Cal 1-6 deg. 270 269.75 270.25
Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25
Cyl.1-2 deg. 315 314.75 315.25
Injection quantity adjustment
Rack position
(15.2)
Vist
V
1.57
1.57
1.57
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
149
147
151
Max. variation between cylinders
%
0
-4
4
Basic
*
PS407980-224*
V
2.45+-0.
01
PS407980-224*
mm
4+-0.05
Injection quantity adjustment_02
Rack position
(8.9)
Vist
V
2.5
2.4
2.6
Pump speed
r/min
350
350
350
Average injection quantity
mm3/st.
16
14
18
Max. variation between cylinders
%
0
-10
10
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
6.3+-0.0
3
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
Governor adjustment
Pump speed
r/min
850--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
800
Advance angle
deg.
0.5
Governor adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
0000001201
Pre-stroke
mm
6.4
6.37
6.43
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
8.5
8
9
Remarks
When the eccentric pin is tightened
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
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:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder.
(3)Pre-stroke: aa
(4)-
----------
aa=6.4+-0.03mm
----------
a=(90deg)
----------
aa=6.4+-0.03mm
----------
a=(90deg)
0000001501
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.
----------
----------
----------
----------
0000001701
(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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----------
----------
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Information:
Introduction
1. Type 2 fuel injector. 2. Two piece follower. 3. Nose cone. 4. Nozzle assembly.Tools are now available for the removal and installation of nose cone (3), on type 2 fuel injectors (1), when it is necessary to replace a nozzle assembly (4). Type 2 fuel injectors can be identified by the two piece follower (2).
5. 1U9395 Plate. 6. 1U8701 Socket.Use 1U9395 Plate (5) with the 6V4830 Fixture Group (not shown) and the procedure given in this instruction, for the removal and installation of nozzle assembly (4).Earlier type 2 injectors have a nose cone that has serrations on its exterior. These serrations will be damaged when the nose cone is removed. A damaged nose cone is not to be used again. A 7C9795 Nose Cone is available for use as a replacement for the original nose cone.The 7C9795 Nose Cone has a hexagon shape on its exterior. This nose cone can be installed and tightened using 1U8701 Socket (6). When the 7C9795 Nose Cone is installed, be sure to tighten it according to the procedure given in this instruction.Removal and Installation of Nose Cone and Nozzle Assembly
1. Remove the original plate from the 6V4830 Fixture Group and install 1U9395 Plate (1).2. Put injector (2) in position on the fixture group. If the exterior of the injector nose cone is a hexagon shape as shown at location (A), use the 1U8701 Socket for nose cone removal. 3. If the exterior of the nose cone has serrations as shown at location (B), use a pipe wrench, as shown, to remove the nose cone. Anytime a pipe wrench is used to remove a nose cone, the nose cone will be damaged. Never use or install a damaged nose cone on an injector. Always install a new 7C9795 Nose Cone as a replacement. 4. After the nose cone has been loosened, use a hammer and 6V4822 Tip Driver (3) to tap the nozzle assembly as shown. This is done to break the connection between the nozzle assembly and the nose cone. Be sure to use only the 6V4822 Tip Driver in this procedure, because use of a standard punch, or any other similar tool will cause damage to the nozzle tip.5. Remove the nose cone and nozzle assembly. 6. Inspect surface (C) in the injector. This is the sealing surface for the nozzle assembly. This surface must be clean and free of any scratches, nicks or burrs. Even a piece of lint from a shop towel can cause a leak and destroy nozzle performance. 7. Remove original O-ring seal (4). Install a new O-ring seal, refer to the Parts Book for the correct part number. Make sure the O-ring seal is not damaged during installation.Use a generous amount of 1P0808 Grease, or a good grade of multi-purpose lubricant, to lubricate the O-ring seal before the nose cone is installed.8. Install new nozzle assembly (5) on the injector. 9. Install and finger tighten the new 7C9795 Nose Cone on the injector. Using a
1. Type 2 fuel injector. 2. Two piece follower. 3. Nose cone. 4. Nozzle assembly.Tools are now available for the removal and installation of nose cone (3), on type 2 fuel injectors (1), when it is necessary to replace a nozzle assembly (4). Type 2 fuel injectors can be identified by the two piece follower (2).
5. 1U9395 Plate. 6. 1U8701 Socket.Use 1U9395 Plate (5) with the 6V4830 Fixture Group (not shown) and the procedure given in this instruction, for the removal and installation of nozzle assembly (4).Earlier type 2 injectors have a nose cone that has serrations on its exterior. These serrations will be damaged when the nose cone is removed. A damaged nose cone is not to be used again. A 7C9795 Nose Cone is available for use as a replacement for the original nose cone.The 7C9795 Nose Cone has a hexagon shape on its exterior. This nose cone can be installed and tightened using 1U8701 Socket (6). When the 7C9795 Nose Cone is installed, be sure to tighten it according to the procedure given in this instruction.Removal and Installation of Nose Cone and Nozzle Assembly
1. Remove the original plate from the 6V4830 Fixture Group and install 1U9395 Plate (1).2. Put injector (2) in position on the fixture group. If the exterior of the injector nose cone is a hexagon shape as shown at location (A), use the 1U8701 Socket for nose cone removal. 3. If the exterior of the nose cone has serrations as shown at location (B), use a pipe wrench, as shown, to remove the nose cone. Anytime a pipe wrench is used to remove a nose cone, the nose cone will be damaged. Never use or install a damaged nose cone on an injector. Always install a new 7C9795 Nose Cone as a replacement. 4. After the nose cone has been loosened, use a hammer and 6V4822 Tip Driver (3) to tap the nozzle assembly as shown. This is done to break the connection between the nozzle assembly and the nose cone. Be sure to use only the 6V4822 Tip Driver in this procedure, because use of a standard punch, or any other similar tool will cause damage to the nozzle tip.5. Remove the nose cone and nozzle assembly. 6. Inspect surface (C) in the injector. This is the sealing surface for the nozzle assembly. This surface must be clean and free of any scratches, nicks or burrs. Even a piece of lint from a shop towel can cause a leak and destroy nozzle performance. 7. Remove original O-ring seal (4). Install a new O-ring seal, refer to the Parts Book for the correct part number. Make sure the O-ring seal is not damaged during installation.Use a generous amount of 1P0808 Grease, or a good grade of multi-purpose lubricant, to lubricate the O-ring seal before the nose cone is installed.8. Install new nozzle assembly (5) on the injector. 9. Install and finger tighten the new 7C9795 Nose Cone on the injector. Using a