107691-3570 ZEXEL 9 400 613 281 BOSCH INJECTION-PUMP ASSEMBLY 9400613281 1076913570 220402341b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 281 9400613281

ZEXEL 107691-3570 1076913570

HINO 220402341B 220402341b

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Buy INJECTION-PUMP ASSEMBLY 107691-3570 zexel genuine, new aftermarket engine parts with delivery

Service parts 107691-3570 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-0740

3. GOVERNOR 105933-1700

4. SUPPLY PUMP 105237-6480

5. AUTOM. ADVANCE MECHANIS 105681-6120

6. COUPLING PLATE 105664-2630

7. COUPLING PLATE

8. _ 159645-4120

9. _

10. NOZZLE AND HOLDER ASSY 105101-8422

11. Nozzle and Holder 23600-3222B

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-3700

14. NOZZLE

15. NOZZLE SET 105019-2170

Include in #1:

107691-3570 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 613 281 9400613281

ZEXEL 107691-3570 1076913570

HINO 220402341B 220402341b

Zexel num

Bosch num

Firm num

Name

107691-3570
107691-3571

9 400 613 281

220402341B HINO

INJECTION-PUMP ASSEMBLY
J08C-UJ * K 14CG TICS MD-TI6 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 1-4-2-6- 3-5

Pre-stroke mm 5.1 5.07 5.13

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 12.7

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 114.5 111.5 117.5

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 8.2+-0.5

Pump speed r/min 440 440 440

Each cylinder's injection qty mm3/st. 13.5 12.15 14.85

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(12.7)

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 114.5 112.5 116.5

Basic *

Fixing the lever *

Boost pressure kPa 62 62

Boost pressure mmHg 465 465

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+2.05

Pump speed r/min 1250 1250 1250

Average injection quantity mm3/st. 124 118 130

Fixing the lever *

Boost pressure kPa 62 62

Boost pressure mmHg 465 465

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.1+-0.0 5

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position R2-1.15

Boost pressure kPa 36 34.7 37.3

Boost pressure mmHg 270 260 280

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position R2[R1-1]

Boost pressure kPa 48.7 48.7 48.7

Boost pressure mmHg 365 365 365

Timer adjustment

Pump speed r/min 1200--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1150

Advance angle deg. 0 -0.3 0

Timer adjustment_03

Pump speed r/min 1290

Advance angle deg. 1.5 1.2 1.8

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)Stop lever's normal position setting: RA (4)Boost compensator stroke: BCL (5)When setting the stop lever after governor adjustment, confirm that rack position Ra (point B) can be obtained at the full setting.
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T1=AH02 RA=(18)mm BCL=1.15+-0.1mm Ra=R1(12.7)+2.05mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
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aa=44mm
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a=8.5deg+-5deg b=(38deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa, stopper bolt setting (2)Speed = bb, rack position = cc (3)Use the hole above R = dd
----------
aa=(18)mm bb=0r/min cc=1.5+-0.1mm dd=40mm
----------
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)Pre-stroke: aa (4)-
----------
aa=5.1+-0.03mm
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a=(30deg)

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.
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0000001701

A : Stopper pin B: Connector
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0000001801

C:Shim
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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.
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0000002201 RACK SENSOR

G:Red paint H:Pump end face P/N: part number of suitable shim (1)Threaded type rack block (2)Welded type rack block Rack sensor adjustment 1. Threaded type rack sensor (-5*20, P type, no TICS rack limit). (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the pump lever. (3)At speed N1 and rack position Ra, adjust the amount that the bobbin is screwed in so that the amp's output voltage is V1. (4)Fix using the nut (F). (5)Affix the caution plate to the upper part of the joint (B). (6)Apply (G) at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the end surface of the pump (H) and the joint (B) 2. Range for screw-in adjustment between the bobbin (A) and the joint (B) is 9 threads. Screw in to the end from (the position where the bobbin (A) is rotated 9 turns). Speed N1, rack position Ra, output voltage V1, rack sensor supply voltage 5+-0.01 (V)
----------
Ra=R1(12.7)+2.05mm N1=1250r/min V1=3+-0.01V
----------

Information:

Exhaust Smoke Can Be Seen While Starting
Possible Causes/Corrections Cold Outside TemperaturesIt may be necessary to use starting aids, or to heat engine oil or coolant at temperatures below -12°C (10°F).Air in Fuel System
With air in the fuel system, the engine will normally be difficult to start, run rough, and release a large amount of white smoke. If the engine will not start, loosen a fuel injection line nut at the through the head adapter and crank the engine until fuel comes out. Tighten the fuel line nut. Start the engine. If the engine still does not run smooth or releases a large amount of white smoke, loosen the fuel line nuts one at a time at the through the head adapters until the fuel that comes out is free of air. Tighten the fuel line nuts. If the air can not be removed in this way, put 35 kPa (5 psi) of air pressure to the fuel tank.
Do not use more than 55 kPa (8 psi) of air pressure in the fuel tank or damage to the tank may result.
Check for leakage at the connections between the fuel tank and the fuel transfer pump. If leaks are found, tighten the connections or replace the lines. It there are no visual leaks, remove the fuel supply line from the tank and connect it to an outside fuel supply. If this corrects the problem, the suction line (standpipe) inside the fuel tank has a leak.Low Quality Fuel
Remove a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, remove fuel from the tank until it is free of water and fill with good quality fuel. For more information see Special Instruction, Form No. SEHS7067, Fuel Recommendations For Caterpillar Diesel Engines.Change the fuel filter and "prime" (remove the air and/or low quality fuel from the fuel system) the fuel system with the fuel priming pump. If there is no water in the fuel, prime and start the engine by using an outside source of fuel. If engine starts correctly using different fuel, remove all fuel from the tank and fill with good quality fuel. Prime the fuel system if necessary.Low Fuel Pressure
Change the primary and secondary fuel filters and check to make sure the fuel lines are not plugged or damaged. If the filters or lines are not the cause, a repair or replacement of the fuel transfer pump is needed.Fuel Injection Timing Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual.Valve Adjustment Not Correct
Check and make necessary adjustments as in Testing and Adjusting section of this Service Manual. Intake valve clearance is 0.38 mm (.015 in) and exhaust valve clearance is 0.76 mm (.030 in).Bad Fuel Nozzle(s)
Remove the fuel nozzles and test as in Testing and Adjusting section of this Service Manual.Low Compression
See Misfiring and Running Rough.Exhaust Smoke Cannot Be Seen While Starting
Possible Causes/CorrectionsNo Fuel in Tank(s)
Check fuel level visually (do not