Information injection-pump assembly
ZEXEL
101603-2360
1016032360
HINO
220009590A
220009590a
Rating:
Service parts 101603-2360 INJECTION-PUMP ASSEMBLY:
1.
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7.
COUPLING PLATE
8.
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9.
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11.
Nozzle and Holder
23600-2980A
12.
Open Pre:MPa(Kqf/cm2)
16.7{170}/21.6{220}
14.
NOZZLE
Cross reference number
Zexel num
Bosch num
Firm num
Name
Information:
Solenoid Valve Replacement
Make reference to the at the beginning of the Testing And Adjusting section.
This procedure assumes that the ether cylinder mounted on the failed solenoid valve may still contain ether and is usable. If the ether cylinder is empty and needs replacement, complete this procedure and then follow the normal cylinder replacement procedure. See Ether Cylinder Replacement.
Solenoid Valve Assembly The solenoid valve itself is not serviceable. The complete solenoid valve assembly must be replaced. This includes the mounting bracket.1. Turn the disconnect switch to the OFF position. 2. Remove the ether cylinder from failed solenoid valve (1).3. Disconnect ether line (2) from the outlet of failed solenoid valve (1).4. Disconnect (unplug) solenoid valve harness connector (3). 5. Remove the reset switch bracket from the solenoid valve by removing two bolts (4). Leave the reset switch and wires intact on the bracket.6. Remove the solenoid valve assembly, which includes the mounting bracket, from the vehicle by removing two bolts (5).
Orifice Fitting And Filter7. Prepare the new solenoid valve for installation by installing a new orifice fitting and filter.
The orifice fitting has left-hand threads.
8. Attach the new solenoid valve and reset switch bracket to the vehicle. Tighten top two bolts (5) and leave lower two bolts (4) loose.
Gasket Filter9. Install a new gasket filter into the inlet of the solenoid valve.10. Install the same ether cylinder. See within Ether Cylinder Replacement. Hand tighten the ether cylinder to the solenoid valve. 11. Adjust the reset switch bracket such that reset switch button (6) depresses as much as possible while contacting the ether cylinder. Tighten lower two bolts (4) which fasten the reset switch bracket and solenoid valve to the vehicle. The reset switch must be adjusted correctly in order for the ether injection system to operate properly. The function of the reset switch is: to be OPEN (depressed switch button) when an ether cylinder is installed, and to be CLOSED (extended switch button) when the ether cylinder is removed. Ether injection is disabled when an ether cylinder is removed (reset switch closed).12. Verify that the reset switch is OPEN by continuity checking between the pin and socket in harness plug (7) of the reset switch. There should be no continuity.13. Reconnect the harnesses to the solenoid valve and the reset switch. Turn the disconnect switch to the ON position.Ether Cylinder Removal
Non-Empty Cylinders
During maintenance or servicing, the ether cylinders may need to be removed when they are not empty (for example, the cylinders may have to be removed to gain access to some other item requiring service). Under these conditions, it is desirable to remove and reinstall the ether cylinders without disturbing the "ether cylinder timers" within the ether injection control. This procedure allows the same ether cylinder to be reinstalled after it has been removed. Normal ether cylinder replacement is performed when the ether cylinder is empty. Normal removal of an empty ether cylinder resets the "ether cylinder timers" within the ether injection control. See Ether Cylinder Replacement. Failure to
Make reference to the at the beginning of the Testing And Adjusting section.
This procedure assumes that the ether cylinder mounted on the failed solenoid valve may still contain ether and is usable. If the ether cylinder is empty and needs replacement, complete this procedure and then follow the normal cylinder replacement procedure. See Ether Cylinder Replacement.
Solenoid Valve Assembly The solenoid valve itself is not serviceable. The complete solenoid valve assembly must be replaced. This includes the mounting bracket.1. Turn the disconnect switch to the OFF position. 2. Remove the ether cylinder from failed solenoid valve (1).3. Disconnect ether line (2) from the outlet of failed solenoid valve (1).4. Disconnect (unplug) solenoid valve harness connector (3). 5. Remove the reset switch bracket from the solenoid valve by removing two bolts (4). Leave the reset switch and wires intact on the bracket.6. Remove the solenoid valve assembly, which includes the mounting bracket, from the vehicle by removing two bolts (5).
Orifice Fitting And Filter7. Prepare the new solenoid valve for installation by installing a new orifice fitting and filter.
The orifice fitting has left-hand threads.
8. Attach the new solenoid valve and reset switch bracket to the vehicle. Tighten top two bolts (5) and leave lower two bolts (4) loose.
Gasket Filter9. Install a new gasket filter into the inlet of the solenoid valve.10. Install the same ether cylinder. See within Ether Cylinder Replacement. Hand tighten the ether cylinder to the solenoid valve. 11. Adjust the reset switch bracket such that reset switch button (6) depresses as much as possible while contacting the ether cylinder. Tighten lower two bolts (4) which fasten the reset switch bracket and solenoid valve to the vehicle. The reset switch must be adjusted correctly in order for the ether injection system to operate properly. The function of the reset switch is: to be OPEN (depressed switch button) when an ether cylinder is installed, and to be CLOSED (extended switch button) when the ether cylinder is removed. Ether injection is disabled when an ether cylinder is removed (reset switch closed).12. Verify that the reset switch is OPEN by continuity checking between the pin and socket in harness plug (7) of the reset switch. There should be no continuity.13. Reconnect the harnesses to the solenoid valve and the reset switch. Turn the disconnect switch to the ON position.Ether Cylinder Removal
Non-Empty Cylinders
During maintenance or servicing, the ether cylinders may need to be removed when they are not empty (for example, the cylinders may have to be removed to gain access to some other item requiring service). Under these conditions, it is desirable to remove and reinstall the ether cylinders without disturbing the "ether cylinder timers" within the ether injection control. This procedure allows the same ether cylinder to be reinstalled after it has been removed. Normal ether cylinder replacement is performed when the ether cylinder is empty. Normal removal of an empty ether cylinder resets the "ether cylinder timers" within the ether injection control. See Ether Cylinder Replacement. Failure to