107692-3002 ZEXEL F 01G 09U 0J2 BOSCH INJECTION-PUMP ASSEMBLY f01g09u0j2 1076923002 220008842a


107692-3002 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH F 01G 09U 0J2 f01g09u0j2
ZEXEL 107692-3002 1076923002
HINO 220008842A 220008842a

Cross reference number

BOSCH F 01G 09U 0J2 f01g09u0j2
ZEXEL 107692-3002 1076923002
HINO 220008842A 220008842a


Zexel num
Bosch num
Firm num
Name
107692-3002 
107692-3003 
F 01G 09U 0J2 
220008842A  HINO
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   131425-0920
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   6.1 6.07 6.13
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   12.4
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   117 114 120
Max. variation between cylinders %   0 -2 2
Basic   *
Fixing the rack   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   4.1+-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   480 480 480
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+-0.03
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(12.4)
Pump speed r/min   750 750 750
Average injection quantity mm3/st.   117 115 119
Basic   *
Fixing the lever   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   4.1+-0.0 5
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+1.1
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   112.5 106.5 118.5
Fixing the lever   *
PS407980-224* V   2.25+-0. 01
PS407980-224* mm   4.1+-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   3 2.95 3.05
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   6.1 6.07 6.13
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

Test data 107692-3002
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)Set stop lever before governor adjustment. [When setting stop lever after governor adjustment, confirm that point B (Ra) can be obtained at full setting.] (4)Stop lever's normal position setting: equivalent to RA (5)Damper spring setting
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T1=AD01 Ra=R1+1.1mm RA=18mm
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Speed control lever angle

Test data 107692-3002
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
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aa=36.5mm
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a=18deg+-5deg b=(40deg)+-3deg

Stop lever angle

Test data 107692-3002
N:Pump normal S:Stop the pump. (1)Set the stopper bolt at rack position = approximately aa. (2)At pump speed bb and rack position cc, set the stopper bolt. (Confirm non-injection at speed = dd.) (3)Use the hole above R = ee
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aa=18mm bb=0r/min cc=1.5+-0.3mm dd=1420r/min ee=37mm
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a=20deg+-5deg b=35deg+-5deg

0000001301

Test data 107692-3002
(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=6.1+-0.03mm
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a=(50deg)

0000001401

Test data 107692-3002
(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

Test data 107692-3002
A : Stopper pin B: Connector
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----------

0000001801

Test data 107692-3002
C:Shim
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0000001901

Test data 107692-3002
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

Test data 107692-3002
(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Mount the joint (B). (2)Select the shim (D) so that the rack limit's rack position is obtained at that time. (3)Install the rod (E) to the block (C). The distance between the pump end face and the rod (E) at rack limit must be L. 2. Rack sensor adjustment (-0020) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set at speed N. (4)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.) (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (6)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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L=38-0.2mm N=1250r/min Ra=R1(12.4)+1.1mm
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0000002301 AIR CYLINDER

Test data 107692-3002
1. Air cylinder adjustment procedure (1)Set the speed lever at idle. (2)Temporarily set the clearance between the speed lever A and the set bolt B at L. (3)Set the speed at N. (4)Apply positive pressure P1 to the air cylinder. (5)Gradually push out the set bolt (B). (6)Tighten the nut (D) at the point where the rack position is Ra at speed N. (7)Apply positive pressure P1 several times. (8)Confirm that the lever returns to the idle position at positive pressure P2.
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L=(6)mm N=320r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2) Ra=8+-0.1mm
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