Information injection-pump assembly
BOSCH
9 400 618 822
9400618822
ZEXEL
107491-3170
1074913170
HINO
220402121A
220402121a

Rating:
Cross reference number
BOSCH
9 400 618 822
9400618822
ZEXEL
107491-3170
1074913170
HINO
220402121A
220402121a
Zexel num
Bosch num
Firm num
Name
107491-3170
9 400 618 822
220402121A HINO
INJECTION-PUMP ASSEMBLY
J05C-TF K
J05C-TF K
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.
407980-2
24*
Digi switch no.
17
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
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
10.9
12.1
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
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
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
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
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
----------
----------
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=39.5mm
----------
a=32deg+-5deg b=34.5deg+-3deg
----------
aa=39.5mm
----------
a=32deg+-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=1.5+-0.1mm cc=28mm
----------
a=40deg+-5deg b=15deg+-5deg
----------
aa=0r/min bb=1.5+-0.1mm cc=28mm
----------
a=40deg+-5deg b=15deg+-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(12.6)+2.15mm
----------
----------
N1=1250r/min Ra=R1(12.6)+2.15mm
----------
0000002301 AIR CYLINDER

1. Air cylinder adjustment procedure
(1)Set the speed lever at idle.
(2)Temporarily set the clearance between the air cylinder (C) and the set bolt (B) to L1.
(3)Set the speed at N.
(4)Apply positive pressure P1 to the air cylinder (C).
(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.
----------
L=(6)mm N=405r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2) Ra=8+-0.1mm
----------
----------
L=(6)mm N=405r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2) Ra=8+-0.1mm
----------
Information:
26Feb2020
U-93
A-70
D-86
O-82
Parts stock action only
PRODUCT IMPROVEMENT PROGRAM FOR INSPECTING AND POSSIBLY REMOVING CERTAIN 471-6029 DEF INJECTOR AND MOUNTING GROUPS FROM DEALER PARTS STOCK
108I 7750 PI70799
Caterpillar’s obligations under this Service Letter are subject to, and shall not apply in contravention of, the laws, rules, regulations, directives, ordinances, orders, or statutes of the United States, or of any other applicable jurisdiction, without recourse or liability with respect to Caterpillar.
When submitting claim for Parts Stock Action, Use the appropriate 99Z as the s/n, the appropriate Service Letter Program Number as the Part number in the Part Causing Failure field, "7751" as the Group Number, "56" as the Description Code.
The information supplied in this service letter may not be valid after the termination date of this program.Do not perform the work outlined in this Service Letter after the termination date without first contacting your Caterpillar product analyst.
TERMINATION DATE
31May2020
PROBLEM
A defined batch of existing 471-6029 DEF Injector and Mounting Groups can fail under certain conditions.
ACTION REQUIRED
Inspect all 471-6029 DEF Injector and Mounting Groups in dealer parts stock.
Open the packaging and visually inspect the DEF injector.
If the DEF injector's upper body molding mark is an A or B, then the DEF injector is acceptable to use. Repackage the DEF injector and mark the packaging as inspected per this program and place the part back into dealer parts stock.
If the DEF injector's upper body molding mark is a 1 or 2, then remove the part from dealer parts stock. Refer to the Parts Disposition.
Image 1 shows the molding marks and location.
Image1
SERVICE CLAIM ALLOWANCES
Submit one claim for all parts removed from dealer parts stock.
PARTS DISPOSITION
NACD:
Hold all 471-6029 DEF Injector and Mounting Groups removed from dealer parts stock for a Parts Return Request (PRR). A Parts Return Request (PRR) will be issued to you through the Send-It-Back process after the claim is submitted. Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.
EAME, LACD, and APD:
Hold all 471-6029 DEF Injector and Mounting Groups removed from dealer parts stock for 30 days for a possible Parts Return Request (PRR). Make sure to list the service letter program number on the packing slip and include the closed work order paperwork. Handle all other parts in accordance with your Warranty Bulletin on warranty parts handling.
If a Parts Return Request (PRR) is not issued to you after 30 days through the Send-It-Back process, handle the parts in accordance with your warranty bulletin on warranty parts handling.
Have questions with 107491-3170?
Group cross 107491-3170 ZEXEL
Hino
107491-3170
9 400 618 822
220402121A
INJECTION-PUMP ASSEMBLY
J05C-TF
J05C-TF