108822-3114 ZEXEL F 01G 09U 0GR BOSCH INJECTION-PUMP ASSEMBLY f01g09u0gr 1088223114 220009123a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH F 01G 09U 0GR f01g09u0gr

ZEXEL 108822-3114 1088223114

HINO 220009123A 220009123a

Service parts 108822-3114 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108082-3270

3. GOVERNOR 105923-1833

4. SUPPLY PUMP 105237-0150

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-2180

7. COUPLING PLATE

8. _ 159600-2820

9. _ 156638-5424

10. NOZZLE AND HOLDER ASSY 105101-7802

11. Nozzle and Holder 23600-2750A

12. Open Pre:MPa(Kqf/cm2) 14.7{150}/21.6{220}

13. NOZZLE-HOLDER 105030-3591

14. NOZZLE

15. NOZZLE SET 105019-0550

Include in #1:

108822-3114 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 01G 09U 0GR f01g09u0gr

ZEXEL 108822-3114 1088223114

HINO 220009123A 220009123a

Zexel num

Bosch num

Firm num

Name

108822-3114
108822-3115

F 01G 09U 0GR

220009123A HINO

INJECTION-PUMP ASSEMBLY
F-4 * 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 134424-4120

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

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

Digi switch no. 41

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-6-2- 7-5-4-3

Pre-stroke mm 7.2 7.17 7.23

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-6 deg. 90 89.75 90.25

Difference between angles 3
Cyl.1-2 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-7 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-5 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-4 deg. 270 269.75 270.25

Difference between angles 7
Cal 1-3 deg. 315 314.75 315.25

Injection quantity adjustment

Adjusting point -

Rack position 13.9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 148 145 151

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4.8+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 7.9+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 14.3 11.3 17.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 7.1+-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(13.9)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 148 146 150

Basic *

Fixing the lever *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4.8+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.95

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 136 130 142

Fixing the lever *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4.8+-0.0 5

0000001601

Pre-stroke mm 7.2 7.17 7.23

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 3.2 3.15 3.25

Output voltage V 2.95 2.94 2.96

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 7.2 7.17 7.23

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

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. (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: RA (5)Damper spring setting
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T1=AD11 Ra=R1+0.95mm RA=(17)mm
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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=88mm
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a=12deg+-5deg b=(35.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)At rack position aa, set the stopper bolt (pump speed bb r/min). (2)Set the stopper bolt at rack position = cc (speed = dd). (3)At pin above R = ee
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aa=0.5+-0.3mm bb=0r/min cc=(17)mm dd=0r/min ee=35mm
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a=15deg+-5deg b=35deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)At the No 1 cylinder's beginning of injection position, stamp an aligning mark on the damper to align with the pointer's groove. (4)Damper (5)Pointer (6)Pre-stroke: aa (7)-
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aa=7.2+-0.03mm
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a=(80deg)

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=1100r/min Ra=R1(13.9)+0.95mm
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0000002301 AIR CYLINDER

(A): Speed lever (B): Adjusting bolt (C): Air cylinder (D): Locknut Within the speed lever's operating range, temporarily tighten the adjusting bolt so that the air cylinder adjusting bolt does not contact the air cylinder (clearance L). (Air cylinder adjustment not necessary.)
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