Information injection-pump assembly
ZEXEL
101601-2370
1016012370
HINO
220002270B
220002270b
Rating:
Cross reference number
ZEXEL
101601-2370
1016012370
HINO
220002270B
220002270b
Zexel num
Bosch num
Firm num
Name
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
134424-0620
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
1-4-2-6-
3-5
Pre-stroke
mm
3.1
3.05
3.15
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
6.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
65.6
64.6
66.6
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
6.6
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
65.5
64
67
Max. variation between cylinders
%
0
-5
5
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
5.2+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
8
7
9
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Timer adjustment
Pump speed
r/min
1000++
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1250
Advance angle
deg.
0.3
0.3
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)RACK LIMIT: RAL
(3)Set the 2nd idle sub spring.
----------
DL=5.7-0.2mm RAL=9.8+0.2mm
----------
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DL=5.7-0.2mm RAL=9.8+0.2mm
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Speed control lever angle
F:Full speed
----------
----------
a=15deg+-5deg
----------
----------
a=15deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=24deg+-5deg b=26deg+-3deg
----------
----------
a=24deg+-5deg b=26deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=21deg+-5deg b=69deg+-5deg
----------
----------
a=21deg+-5deg b=69deg+-5deg
0000001501 MICRO SWITCH
Switch adjustment
Adjust the bolt so that the lower lever position is obtained when the switch is turned ON.
(1)Speed N1
(2)Rack position Ra
----------
N1=375-25r/min Ra=5.5mm
----------
----------
N1=375-25r/min Ra=5.5mm
----------
Information:
start by: a) separation of governor from fuel injection pump housing 1. Remove the cover (1) for the rack centering pin. Move the rack until the centering pin can be pushed down. Install the cover so the edge of the cover holds the pin down. 2. Remove the protection cap and felt washer (2).3. Install wrench (A) and remove bushing (3).4. Remove seal (4). 5. Install extractor (B). Hold the rack toward the driven end of the pump housing and remove the fuel injection pump.
Do not remove fuel injection pumps without the rack centering pin installed and the rack held toward the driven end of the pump housing.
6. Remove spacer (10). Put identification on spacers (10), fuel injection pumps, and lifters (14) as to their respective location in the pump housing. These parts must be installed back in their original positions in the pump housing.7. Disassemble injection pumps using the following method: a) Remove bonnet (5), ring (8), spring (7), and check valve (6) from barrel (9).b) Remove plunger assembly (11), washer (12), and spring (13) from barrel (9).
During disassembly and assembly of fuel injection pumps, use much care to prevent damage to the surfaces of plunger assemblies. The barrel and plunger assemblies have a special fit with each other, and are not to be used with other barrels or plunger assemblies.
8. Remove the cover for the rack centering pin. Remove the spring and pin.9. Remove the rack from the pump housing. 10. Remove lifters (14). Put identification on lifters so they can be installed back into their original positions in housing. 11. Remove the bolt, lock and plate (17).12. Remove spring (15) and gear assembly (18) from the camshaft. 13. Remove the camshaft (19) from the pump housing. 14. Install tool group (C) and remove the camshaft bearings from the pump housing.15. Remove the two rack bearings (16) from the pump housing.Assemble Fuel Injection Pump Housing
1. Install camshaft bearings in pump housing with tool group (C). Install the bearing at governor end of pump housing so the oil hole in bearing is in alignment with oil hole in pump housing. Install the two bearings on each end of housing so the edge of bearing will be even with end of pump housing. 2. Install the two rack bearings in pump housing with tooling (D). Install the bearing at governor end of pump housing so it is .195 .005 in. (4.95 0.13 mm) inside end of housing. Install rack bearing at other end of housing so it is even with face of pump housing. If rack bearing at other end of housing has a tab, install with tool group (F).3. Put clean oil on the camshaft and install
Do not remove fuel injection pumps without the rack centering pin installed and the rack held toward the driven end of the pump housing.
6. Remove spacer (10). Put identification on spacers (10), fuel injection pumps, and lifters (14) as to their respective location in the pump housing. These parts must be installed back in their original positions in the pump housing.7. Disassemble injection pumps using the following method: a) Remove bonnet (5), ring (8), spring (7), and check valve (6) from barrel (9).b) Remove plunger assembly (11), washer (12), and spring (13) from barrel (9).
During disassembly and assembly of fuel injection pumps, use much care to prevent damage to the surfaces of plunger assemblies. The barrel and plunger assemblies have a special fit with each other, and are not to be used with other barrels or plunger assemblies.
8. Remove the cover for the rack centering pin. Remove the spring and pin.9. Remove the rack from the pump housing. 10. Remove lifters (14). Put identification on lifters so they can be installed back into their original positions in housing. 11. Remove the bolt, lock and plate (17).12. Remove spring (15) and gear assembly (18) from the camshaft. 13. Remove the camshaft (19) from the pump housing. 14. Install tool group (C) and remove the camshaft bearings from the pump housing.15. Remove the two rack bearings (16) from the pump housing.Assemble Fuel Injection Pump Housing
1. Install camshaft bearings in pump housing with tool group (C). Install the bearing at governor end of pump housing so the oil hole in bearing is in alignment with oil hole in pump housing. Install the two bearings on each end of housing so the edge of bearing will be even with end of pump housing. 2. Install the two rack bearings in pump housing with tooling (D). Install the bearing at governor end of pump housing so it is .195 .005 in. (4.95 0.13 mm) inside end of housing. Install rack bearing at other end of housing so it is even with face of pump housing. If rack bearing at other end of housing has a tab, install with tool group (F).3. Put clean oil on the camshaft and install