101402-2270 ZEXEL 9 400 613 867 BOSCH INJECTION-PUMP ASSEMBLY 9400613867 1014022270 220204380a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 613 867 9400613867

ZEXEL 101402-2270 1014022270

HINO 220204380A 220204380a

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Service parts 101402-2270 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9290

3. GOVERNOR 105400-8290

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156636-4821

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4320

11. Nozzle and Holder 23600-1710

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-6240

15. NOZZLE SET

Include in #1:

101402-2270 as INJECTION-PUMP ASSEMBLY

108822-3265 as _

Cross reference number

BOSCH 9 400 613 867 9400613867

ZEXEL 101402-2270 1014022270

HINO 220204380A 220204380a

Zexel num

Bosch num

Firm num

Name

101402-2270

9 400 613 867

220204380A HINO

INJECTION-PUMP ASSEMBLY
W04C-T * K 14BC INJECTION PUMP ASSY PE4A,5A, PE

Calibration Data:

Adjustment conditions

Test oil
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

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.17 3.23

Beginning of injection position
Drive 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 A

Rack position 8.3

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 72.5 70.5 74.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 5.9+-0.5

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 10 8.5 11.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

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
----------
K=16
----------

Speed control lever angle

F:Full speed I:Idle S:Stop
----------

----------
a=3deg+-5deg b=20deg+-5deg c=32deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position aa or less, pump speed bb
----------
aa=5.4mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-5deg

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)

Information:

Image1.1.1
4) Remove the 90 degree pressure line fitting under the sensor box.
5) Remove the 90 degree pressure line fitting from the DPF center section that is closest to the outlet side.
6) The new pressure line that will fit into the DPF center section will need to be installed into the port in which the thermocouple was fitted. The existing thermocouple will need to be fitted into the port in which the old pressure line was fitted.
Swapping of the ports is only necessary on the outlet side of the center section.
Image1.2.1
Image1.2.2
7) Install the 7W-3556 washer on the 304-8042 straight fitting. Install the straight fitting into the DPF pressure port (towards the outlet side) in which the thermocouple was previously installed, tighten to a torque of 24 +/- 4 Nm (212 +/- 35 lb-in). Screw the 2N-8142 tee fitting onto that straight fitting and tighten to a torque of 24 +/- 4 Nm (212 +/- 35 lb-in).
Image1.3.1
8) Replace the O-ring on the sensor box where the old 90 degree pressure line fitting was located. Install the 4S-4857 tee fitting in the sensor box to a torque of 11 +/- 1 Nm (97 +/- 9 lb-in).
Image1.4.1
9) Where applicable, perform Service Letter REBE3391 at this time.
10) Install sensor box bracket and existing heat shield. Tighten all six bolts to a torque of 12 +/- 3 Nm (106 +/- 27 lb-in).
11) Install sensor box, new pressure lines (tube assemblies), thermocouples onto DPF, and cable straps.
Reference appropriate Disassembly and Assembly manual for proper torque and use of anti-seize.
Image1.5.1
12) Start the engine and use CAT ET to ensure that the status parameter Diesel Particulate Trap #1 Differential Pressure has a value greater than zero. Also, ensure status parameters Diesel Particulate Trap #1 Intake Temperature, and Diesel Particulate Trap #1 Outlet Temperature show reasonable values and increase with the rising exhaust temperatures.