107491-3081 ZEXEL 9 400 619 964 BOSCH INJECTION-PUMP ASSEMBLY 9400619964 1074913081 220401070b


107491-3081 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 619 964 9400619964
ZEXEL 107491-3081 1074913081
HINO 220401070B 220401070b

Service parts 107491-3081 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 107049-0011
3. GOVERNOR 105933-0721
4. SUPPLY PUMP 105237-6390
5. AUTOM. ADVANCE MECHANIS 105681-5750
6. COUPLING PLATE 105664-2351
7. COUPLING PLATE
9. _
10. NOZZLE AND HOLDER ASSY 105160-4892
11. Nozzle and Holder 236003210C
12. Open Pre:MPa(Kqf/cm2) 21.6{220}
13. NOZZLE-HOLDER 105030-3680
14. NOZZLE 105025-1940
15. NOZZLE SET

Include in #1:

107491-3081 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 619 964 9400619964
ZEXEL 107491-3081 1074913081
HINO 220401070B 220401070b


Zexel num
Bosch num
Firm num
Name
107491-3081 
107491-3082 
9 400 619 964 
220401070B  HINO
INJECTION-PUMP ASSEMBLY
J05C-TD * K

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.   123.5 120.5 126.5
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   440 440 440
Average injection quantity mm3/st.   16 15 17
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.   123.5 121.5 125.5
Basic   *
Fixing the lever   *
Boost pressure kPa   50.7 50.7
Boost pressure mmHg   380 380
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+2.7
Pump speed r/min   1250 1250 1250
Average injection quantity mm3/st.   138 132 144
Fixing the lever   *
Boost pressure kPa   50.7 50.7
Boost pressure mmHg   380 380
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   R2-1.65
Boost pressure kPa   24 22.7 25.3
Boost pressure mmHg   180 170 190
Boost compensator adjustment_02
Pump speed r/min   400 400 400
Rack position   R2(R1-1. 3)
Boost pressure kPa   37.3 37.3 37.3
Boost pressure mmHg   280 280 280
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

Test data 107491-3081
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=AF26 BCL=1.65+-0.1mm
----------

Speed control lever angle

Test data 107491-3081
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=40mm
----------
a=5deg+-5deg b=37deg+-3deg

Stop lever angle

Test data 107491-3081
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

Test data 107491-3081
(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

Test data 107491-3081
(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

Test data 107491-3081
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107491-3081
C:Shim
----------

----------

0000001901

Test data 107491-3081
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

Test data 107491-3081
(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)+2.7mm
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Group cross 107491-3081 ZEXEL

Hino 

 
220401070A 
INJECTION-PUMP ASSEMBLY
J05C-TD
107491-3081  

107491-3082 
9 400 619 964 
220401070B 
INJECTION-PUMP ASSEMBLY
J05C-TD
 
 
INJECTION-PUMP ASSEMBLY
 
 
INJECTION-PUMP ASSEMBLY

Hino 

9 400 618 818 
220401070C 
INJECTION-PUMP ASSEMBLY
J05C-TD
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