Information injection-pump assembly
BOSCH
F 01G 09U 0D0
f01g09u0d0
ZEXEL
107491-3071
1074913071
HINO
220009571A
220009571a
Rating:
Service parts 107491-3071 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
23600-2970A
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Include in #1:
107491-3071
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
F 01G 09U 0D0
f01g09u0d0
ZEXEL
107491-3071
1074913071
HINO
220009571A
220009571a
Zexel num
Bosch num
Firm num
Name
F 01G 09U 0D0
220009571A HINO
INJECTION-PUMP ASSEMBLY
J05C-TB * K 14CF TICS MD-TI4 TICS
J05C-TB * K 14CF TICS MD-TI4 TICS
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
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
465
465
465
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
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
R2-1.95
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
40
40
40
Boost pressure
mmHg
300
300
300
Timer adjustment
Pump speed
r/min
1170--
Advance angle
deg.
0
0
0
Remarks
Start
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
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
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
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
----------
----------
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=7deg+-5deg b=39.5deg+-3deg
----------
aa=40mm
----------
a=7deg+-5deg b=39.5deg+-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
----------
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)
----------
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
----------
----------
N1=1250r/min Ra=R1(11.7)+3.1mm
----------
Information:
TERMINATION DATE
31Aug2019
PROBLEM
The existing injector nozzles can leak diesel on certain D8R Track-Type Tractors. If the existing injector nozzles leak it can cause dilution of the engine oil and affect engine performance.
AFFECTED PRODUCT
Model Identification Number
D8R RJM00517-00529, 531-547
PARTS NEEDED
Qty
Part Number Description
1 1R0716 FILTER AS-LUBE (After Failure Only)
2 5P5678 SEAL
6 7W2315 RETAINER
6 1291351 NOZZLE AS-DI F V
6 2033940 SEAL-O-RING
6 4640509 SEAL-O-RING
1 OIL_BULK See OMM - Cat DEO 42 L (After Failure Only as Req)
In order to allow equitable parts availability to all participating dealers, please limit your initial parts order to not exceed 32% of dealership population. This is an initial order recommendation only, and the ultimate responsibility for ordering the total number of parts needed to satisfy the program lies with the dealer.
ACTION REQUIRED
Replace the injector nozzles.
For the repair of the Affected Product, ensure the injector nozzles have a date code of "CAT 01 A 17" (1st Jan 2017) or a later date. See Image 1 with date code details (example date 7th Dec 2016). Image 2 shows the general ID location on an injector nozzle.
Refer to Disassembly and Assembly, SENR1029 for removing and installing the valve covers, valve cover bases, and replacing injectors.
For an injector nozzle replacement, after failure, when a leak has occurred, replace the engine oil and filter.
Image1
Image2
SERVICE CLAIM ALLOWANCES
Product smu/age whichever comes first Caterpillar Dealer Suggested Customer Suggested
Parts % Labor Hrs% Parts % Labor Hrs% Parts % Labor Hrs%
0-5000 hrs,
0-48 mo 100.0% 100.0% 0.0% 0.0% 0.0% 0.0%
This is a 3.0-hour job
An additional 1 hour is allowed for after failure (to replace oil and filter).
PARTS DISPOSITION
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.