Information injection-pump assembly
BOSCH
9 400 611 784
9400611784
ZEXEL
101401-2375
1014012375
HINO
220205263A
220205263a
Rating:
Service parts 101401-2375 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-3180A
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 611 784
9400611784
ZEXEL
101401-2375
1014012375
HINO
220205263A
220205263a
Zexel num
Bosch num
Firm num
Name
101401-2375
9 400 611 784
220205263A HINO
INJECTION-PUMP ASSEMBLY
W04C-TI K 14BD INJECTION PUMP ASSY PE4AD PE
W04C-TI K 14BD INJECTION PUMP ASSY PE4AD PE
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
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
134424-0920
Overflow valve opening pressure
kPa
162
147
177
Overflow valve opening pressure
kgf/cm2
1.65
1.5
1.8
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
4.3
4.27
4.33
Beginning of injection position
Drive side NO.1
Drive 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
A
Rack position
11.5
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
115
113
117
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the lever
*
Boost pressure
kPa
45.3
45.3
Boost pressure
mmHg
340
340
Injection quantity adjustment_02
Adjusting point
C
Rack position
8.4+-0.5
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
10
8.5
11.5
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
R1-1.7
Boost pressure
kPa
4
2.7
5.3
Boost pressure
mmHg
30
20
40
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
R1(11.5)
Boost pressure
kPa
32
32
32
Boost pressure
mmHg
240
240
240
Timer adjustment
Pump speed
r/min
1300--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1250
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
3
2.7
3.3
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)Set idle sub-spring
(4)Main spring setting
(5)Boost compensator stroke: BCL
----------
K=9 BCL=1.7+-0.1mm
----------
----------
K=9 BCL=1.7+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=11deg+-5deg b=26deg+-5deg
----------
----------
a=11deg+-5deg b=26deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
(2)Pump speed aa and rack position bb (to be sealed at delivery)
(3)Use the hole above R = cc
----------
aa=0r/min bb=1-0.5mm cc=25mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.5mm cc=25mm
----------
a=21deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
Information:
Problem
The fuel lines on certain 3408 Generator Set, Industrial, and Marine engines may fail. New fuel line groups can be installed that have a longer service life.
Affected Product
Model & Identification Number
3408 (67U12405-15199; 78Z2829-4522; 99U5985-7229)
Parts Needed
1 - 6I0030 Fuel Line Group6 - 5M2894 Washer6 - 0S0509 BoltAdditional Parts Needed For DIT Engines (Non-Aftercooled)
5 - 5M2894 Washer1 - 4P8261 Bracket1 - 4P8385 Bracket2 - 5P0537 Washer5 - 0S1571 Bolt2 - 0S1615 Bolt3 - 8T1296 WasherAction Required
Parts Stock
Make sure that all 7C6931, 7C6932, 7C6933, 7C6934, 7C6935, 7C6936, 7C6937 and 7C6938 Fuel Lines were removed from parts stock while implementing Product Support Program PS4737.
Affected Product
Remove the existing fuel lines and install the new fuel injection line groups as a group. See the attached rework procedure.
Do not over tighten the screws of the metal-to- metal fuel line clamps. Use a 6V6069 Torgue Screwdriver or similar tool to tighten the screw to a torgue of 2.25 N m (20 lb in).
Service Claim Allowances
Parts Stock
Refer to the Product Support Program PS4737.
Affected Product
This is a 2.2-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Refer to the parts list and illustrations. Replace the existing fuel lines and their related parts with the new 6I0030 Fuel Line Group.
To insure that the clamp locations are correct, install fuel line group as assembled. In a case where it is necessary to remove the clamps, mark their locations to insure the correct position when assembling.
1. Clean and paint the new 6I0030 Fuel Line Group before proceeding to the job site.A) Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the lines.B) Clean and paint the fuel line group.C) After drying, do not remove the plastic plugs and caps until the fuel line group is ready to be installed on the engine. Transport the fuel line group in it's original shipping box. If the engine to be reworked is non-aftercooled, also clean and pre-paint the new 4P8385 and 4P8261 Brackets.
2. Remove all the mounting bolts from the fuel line bracket at the aftercooler housing on DITA engines or at the 6N1671 Bracket on DIT engines. The 6N1671 Bracket in the vee of the DIT (non- aftercooled) engines is used to support the fuel line brackets. This bracket is part of the 6N1672 Fastener Group, Affected Product not having an aftercooler required a new two piece bracket.
3. Disconnect all the fuel line nuts at the fuel injection pump and at the adapters in the valve cover bases.4. a) Remove the old fuel line group.b) On DIT engines only, remove the 6N1671 Bracket from the vee of the engine and install the new brackets. Illustrations 2 and 3 show how the new brackets are installed. The 4P8385 Bracket and 4P8261 Bracket are the 2 main parts of this group. Five 0S1571 Bolts and five 5M2894 Washers attach the assembly to the block. To align the assembly correctly, three 8T1296 Washers are reguired to shim the brackets to the block (see Illustration
The fuel lines on certain 3408 Generator Set, Industrial, and Marine engines may fail. New fuel line groups can be installed that have a longer service life.
Affected Product
Model & Identification Number
3408 (67U12405-15199; 78Z2829-4522; 99U5985-7229)
Parts Needed
1 - 6I0030 Fuel Line Group6 - 5M2894 Washer6 - 0S0509 BoltAdditional Parts Needed For DIT Engines (Non-Aftercooled)
5 - 5M2894 Washer1 - 4P8261 Bracket1 - 4P8385 Bracket2 - 5P0537 Washer5 - 0S1571 Bolt2 - 0S1615 Bolt3 - 8T1296 WasherAction Required
Parts Stock
Make sure that all 7C6931, 7C6932, 7C6933, 7C6934, 7C6935, 7C6936, 7C6937 and 7C6938 Fuel Lines were removed from parts stock while implementing Product Support Program PS4737.
Affected Product
Remove the existing fuel lines and install the new fuel injection line groups as a group. See the attached rework procedure.
Do not over tighten the screws of the metal-to- metal fuel line clamps. Use a 6V6069 Torgue Screwdriver or similar tool to tighten the screw to a torgue of 2.25 N m (20 lb in).
Service Claim Allowances
Parts Stock
Refer to the Product Support Program PS4737.
Affected Product
This is a 2.2-hour job.
Parts Disposition
Handle the parts in accordance with your Warranty Bulletin on warranty parts handling.
Attach. (1-Rework Procedure)Rework Procedure
Refer to the parts list and illustrations. Replace the existing fuel lines and their related parts with the new 6I0030 Fuel Line Group.
To insure that the clamp locations are correct, install fuel line group as assembled. In a case where it is necessary to remove the clamps, mark their locations to insure the correct position when assembling.
1. Clean and paint the new 6I0030 Fuel Line Group before proceeding to the job site.A) Install 5F2807 Plastic Caps and 2F2990 Plastic Plugs on the ends of the lines.B) Clean and paint the fuel line group.C) After drying, do not remove the plastic plugs and caps until the fuel line group is ready to be installed on the engine. Transport the fuel line group in it's original shipping box. If the engine to be reworked is non-aftercooled, also clean and pre-paint the new 4P8385 and 4P8261 Brackets.
2. Remove all the mounting bolts from the fuel line bracket at the aftercooler housing on DITA engines or at the 6N1671 Bracket on DIT engines. The 6N1671 Bracket in the vee of the DIT (non- aftercooled) engines is used to support the fuel line brackets. This bracket is part of the 6N1672 Fastener Group, Affected Product not having an aftercooler required a new two piece bracket.
3. Disconnect all the fuel line nuts at the fuel injection pump and at the adapters in the valve cover bases.4. a) Remove the old fuel line group.b) On DIT engines only, remove the 6N1671 Bracket from the vee of the engine and install the new brackets. Illustrations 2 and 3 show how the new brackets are installed. The 4P8385 Bracket and 4P8261 Bracket are the 2 main parts of this group. Five 0S1571 Bolts and five 5M2894 Washers attach the assembly to the block. To align the assembly correctly, three 8T1296 Washers are reguired to shim the brackets to the block (see Illustration
Have questions with 101401-2375?
Group cross 101401-2375 ZEXEL
Hino
Hino
101401-2375
9 400 611 784
220205263A
INJECTION-PUMP ASSEMBLY
W04C-TI
W04C-TI