107491-3102 ZEXEL 9 400 618 820 BOSCH INJECTION-PUMP ASSEMBLY 9400618820 1074913102 220401252a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 820 9400618820

ZEXEL 107491-3102 1074913102

HINO 220401252A 220401252a

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Cross reference number

BOSCH 9 400 618 820 9400618820

ZEXEL 107491-3102 1074913102

HINO 220401252A 220401252a

Zexel num

Bosch num

Firm num

Name

107491-3102
107491-3120

9 400 618 820

220401252A HINO

INJECTION-PUMP ASSEMBLY
J05C-TF K 14CF INJECTION PUMP ASSY 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. 407980-2 24*

Digi switch no. 17

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 12.6

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 118 115 121

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-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 505 505 505

Each cylinder's injection qty mm3/st. 11.5 10.5 12.5

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* 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(12.6)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 118 116 120

Basic *

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Injection quantity adjustment_04

Adjusting point B

Rack position R1+2.15

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 130 124 136

Fixing the lever *

Boost pressure kPa 44 44

Boost pressure mmHg 330 330

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Injection quantity adjustment_05

Adjusting point C

Rack position (R2-0.55 )

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 102.5 99.5 105.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position (R2-0.55 )

Boost pressure kPa 22 20.7 23.3

Boost pressure mmHg 165 155 175

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R2(R1-0. 95)

Boost pressure kPa 30.7 30.7 30.7

Boost pressure mmHg 230 230 230

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 24 23.5 24.5

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 24 23.5 24.5

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 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)Boost compensator stroke: BCL
----------
T1=AF54 BCL=(0.55)+-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=5deg+-5deg b=34.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)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. (2)Pump speed aa, rack position bb (3)Use the hole above R = cc
----------
aa=0r/min bb=3.5+-0.1mm cc=35mm
----------
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(12.6)+2.15mm
----------

Information:

TECHNICAL INFORMATION BULLETIN July 7, 2004
Engines
Machines 3054E (304, CRX)
3056E (356, CPT)
315C (ANF)
320C (CCD)
924G (DDA, DFZ, RBB, WGX, WMB)
928G (DJD, WLG)
AP-655C (CDG)
CP-563E (BWE, CNT)
CP-573E (ASY)
CS-563E (ASA, CNG)
CS-583E (DAJ)
CS-663E (DAG)
IT28G (DBT, EWF, WAC)
M313C (BDR)
M315C (BDM)
M316C (BDX)
M318C (BCZ)
M322C (BDK)
TH330B (SLB)
Component Code 1251SUBJECT: Replace Failed 3054E and 3056E Fuel Injection Pumps with New Pumps from Cat Parts
PROBLEM:
The 3054E and 3056E engines use electronic Bosch fuel injection pumps. These are new engine applications for these pumps. Therefore, initially, Bosch is requesting that all failed pumps are to be replaced by new pumps from Cat Parts. Replaced pumps are to be returned to Bosch through Peoria, IL or Peterborough, U.K. as described below, depending on location.
SOLUTION:
Failed fuel injection pumps are to be replaced by new pumps out of Cat Parts. Pumps should only be replaced after a full diagnostic check of the Engine and Machine. Troubleshooting Guide, RENR2417, should be used in order to perform the full diagnostic check. Replaced pumps must be returned to Caterpillar Inc. for forwarding to the supplier for full failure analysis.
Pumps from NACD and LACD territories are to be packaged and shipped to:
Caterpillar Service Claims Room
8201 N. University
Peoria, IL 61615 USA
Attn: 3000 Series Engine Service Engineer
Pumps from EAME and APD territories are to be packaged and shipped to:
Perkins Engines Ltd.
Return Parts Centre-C/O Ron Chandler
Peterborough PE1 5NA
U.K.
All failure information is to be submitted with each pump. Dealers are requested to supply FULL details regarding their investigations into the failure of the pump. This information will allow for a more detailed analysis of the pump failure. Attach the normal service claim form. The following list represents the minimum amount of additional information that should be submitted with the faulty pump and the service claim form.
A breakdown of the fault finding process employed using RENR2417
Details of the failure including symptoms that were experienced (Hard to start, etc?)
Screen prints from Caterpillar Electronic Technician (Cat ET) describing both the logged and active fault codes at the time of investigation
Other relevant details from customers include engine and machine history and the usage at the time of the incident
Dealers from EAME should email the above information to Alex Radjenovic at Radjenovic_Alex@perkins.com
Dealers from NACD and LACD should email the above information to Robert Stoetzer at Stoetzer_Robert_A
All returned fuel injection pump ports must be sealed prior to shipment to prevent contamination. The protective caps used on the new pump ports MUST be transferred to the failed pump ports prior to return shipment to avoid contamination in route to the supplier. Also, it is imperative that the pump be protected against damage during transit. Damage during transit may prevent assessment by the supplier.
Dealers in the NACD territory are to follow the established parts return procedures per Service Warranty Bulletin No. 7.1.
Dealers outside of the NACD territory are required to pay for the shipping cost of the returned pump, then claim the shipping cost as a miscellaneous expense on the warranty claim.
COPYRIGHT 2004 CATERPILLAR
ALL RIGHTS RESERVED