107491-3061 ZEXEL F 01G 09U 0CX BOSCH INJECTION-PUMP ASSEMBLY f01g09u0cx 1074913061 220009561a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH F 01G 09U 0CX f01g09u0cx

ZEXEL 107491-3061 1074913061

HINO 220009561A 220009561a

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Buy INJECTION-PUMP ASSEMBLY 107491-3061 zexel genuine, new aftermarket engine parts with delivery

Service parts 107491-3061 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107049-0010

3. GOVERNOR 105933-0591

4. SUPPLY PUMP 105237-6390

5. AUTOM. ADVANCE MECHANIS 105681-5630

6. COUPLING PLATE 105664-2351

7. COUPLING PLATE

8. _ 159600-7221

9. _

10. NOZZLE AND HOLDER ASSY 105160-4601

11. Nozzle and Holder 23600-2970A

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

13. NOZZLE-HOLDER 105030-3680

14. NOZZLE 105025-1260

15. NOZZLE SET

Include in #1:

107491-3061 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH F 01G 09U 0CX f01g09u0cx

ZEXEL 107491-3061 1074913061

HINO 220009561A 220009561a

Zexel num

Bosch num

Firm num

Name

107491-3061
107491-3062

F 01G 09U 0CX

220009561A HINO

INJECTION-PUMP ASSEMBLY
J05C-TB * K 14CF TICS MD-TI4 TICS

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. 407910-3 03*

Selector switch no. 03

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

Digi switch no. 16

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-3-4-2

Pre-stroke mm 5.1 5.07 5.13

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point -

Rack position 11.7

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 127.5 124.5 130.5

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.1+-0.0 5

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 6+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 18 17 19

Max. variation between cylinders % 0 -15 15

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 5+-0.03

PS407910-303* V V1-0.05+ -0.01

PS407910-303* mm 5+-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(11.7)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 127.5 125.5 129.5

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.1+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+3.1

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 147 141 153

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

PS407910-303* V 1.75+-0. 01

PS407910-303* mm 3.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R1-1.95

Boost pressure kPa 26.7 25.4 28

Boost pressure mmHg 200 190 210

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2(R1-1. 4)

Boost pressure kPa 39.9 39.9 39.9

Boost pressure mmHg 300 300 300

Timer adjustment

Pump speed r/min 1170--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1120

Advance angle deg. 0 -0.3 0

Timer adjustment_03

Pump speed r/min 1250-50

Advance angle deg. -1.5 -1.8 -1.2

Remarks
Finish

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2 1.95 2.05

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.1 5.07 5.13

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_03

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

_04

CU407910-303* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2 1.95 2.05

Output voltage V 1.17 1.16 1.18

Adjustment *

_05

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.1 5.07 5.13

Output voltage V 2.8 2.6 3

Confirmation *

Remarks
Output voltage V1

_06

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 0.95

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)Boost compensator stroke: BCL
----------
T1=AE63 BCL=1.95+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=6deg+-5deg b=40.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Speed = bb, rack position = cc (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.
----------
aa=35mm bb=0r/min cc=1.5+-0.1mm
----------
a=10.5deg+-5deg b=40deg+-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)-
----------
aa=5.1+-0.03mm
----------
a=(80deg)

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.
----------

----------

0000001701

A : Stopper pin B: Connector
----------

----------

0000001801

C:Shim
----------

----------

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 clockwise (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 counterclockwise 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

(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)
----------
N1=1250r/min Ra=R1(11.7)+3.1mm
----------

Information:

PARTS NEEDED
No parts needed for this program
ACTION REQUIRED
****Parts Stock ****
Rework the following engines in dealer parts stock:
3512 Engine Arrangement 0R3982, 0R9844, 10R6700 - EEE00102-EEE00149
3516 Engine Arrangement Number 0R3953, 0R3983, 0R9845, 10R2854, 10R6702, 20R2775, 20R5421 - WE300101-WE300159, WE300161-WE300173, WE300175-WE300178, WE300180-WE300188
3508 Engine Arrangement Number 0R3950, 0R3951, 0R8550, 0R8551, 0R8553, 0R9840, 0R9841, 0R9842, 10R5596, 10R9195 - HEE00101-HEE00192, HEE00196-HEE00223, HEE00227-HEE00230
3516 Engine Arrangement Number 10R2853, 20R2776, 20R3194, 20R3537, 20R6114, 20R6115, 20R1116 - DE300101-DE300181, DE300183-DE300200, DE300202-DE300208
3512 Engine Arrangement Number 10R9209, 20R2674 - EEZ00101-EEZ00127, EEZ00130-EEZ00136, EEZ00138-EEZ00143
3524 Engine Arrangement Number 10R7929 - XEE00101-XEE00139
3516 Engine Arrangement Number 20R7272 - AW300101-AW30109
3512 Engine Arrangement Number 20R3658 - EEK00101
Check valve lash setting on each cylinder of the engine using SENR2362, Valve Lash Check. If found out of spec then adjust using SENR2362, Valve Lash Bridge Adjustment. Use SENR2362, Fuel Injector Timing to verify correct injector lash.
****Affected Product****
This program applies only if the Affected Product is equipped with one of the following Reman Engines:
3512 Engine Arrangement 0R3982, 0R9844, 10R6700 - EEE00102-EEE00149
3516 Engine Arrangement Number 0R3953, 0R3983, 0R9845, 10R2854, 10R6702, 20R2775, 20R5421 - WE300101-WE300159, WE300161-WE300173, WE300175-WE300178, WE300180-WE300188
3508 Engine Arrangement Number 0R3950, 0R3951, 0R8550, 0R8551, 0R8553, 0R9840, 0R9841, 0R9842, 10R5596, 10R9195 - HEE00101-HEE00192, HEE00196-HEE00223, HEE00227-HEE00230
3516 Engine Arrangement Number 10R2853, 20R2776, 20R3194, 20R3537, 20R6114, 20R6115, 20R1116 - DE300101-DE300181, DE300183-DE300200, DE300202-DE300208
3512 Engine Arrangement Number 10R9209, 20R2674 - EEZ00101-EEZ00127, EEZ00130-EEZ00136, EEZ00138-EEZ00143
3524 Engine Arrangement Number 10R7929 - XEE00101-XEE00139
3516 Engine Arrangement Number 20R7272 - AW300101-AW30109
3512 Engine Arrangement Number 20R3658 - EEK00101
Check valve lash setting on each cylinder of the engine using SENR2362, Valve Lash Check. If found out of spec then adjust using SENR2362, Valve Lash Bridge Adjustment. Use SENR2362, Fuel Injector Timing to verify correct injector lash.
SERVICE CLAIM ALLOWANCES
****Parts Stock****
Submit one claim for all engines reworked from dealer parts stock.
This is a 4 hour job for a 3508
An additional 2 hours for a 3512
An additional 4 hours for a 3516
An additional 8 hours for a 3524
Include the engine serial number(s) of the Reman engine(s) that was/were reworked in the claim.
****Affected Product****
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-250 hrs,
0-3 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 4.0-hour job
If there has been a previous repair, part age/hours will apply. Retain a copy of the previous repair invoice in the dealer's records for audit purposes, and specify repair date and machine hours in the "Additional Comments" section of the warranty claim.
4.0-hours for a 3508.
An additional 2 hours for a 3512
An additional 4 hours for a 3516
An additional 8 hours for a 3524
Part age/hours is based on engine age/hours.
Include the engine serial number of the Reman engine that was reworked in the claim.
PARTS DISPOSITION
****Parts Stock****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
****Affected Product****
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.