Information injection-pump assembly
ZEXEL
101603-2480
1016032480
HINO
220205130A
220205130a
Rating:
Service parts 101603-2480 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2820A
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
101603-2480
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-6581
as _
Cross reference number
ZEXEL
101603-2480
1016032480
HINO
220205130A
220205130a
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
134424-0920
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
1-4-2-6-
3-5
Pre-stroke
mm
4.8
4.77
4.83
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
10.1
Pump speed
r/min
1075
1075
1075
Average injection quantity
mm3/st.
119
117.5
120.5
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
28.7
28.7
Boost pressure
mmHg
215
215
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-0.5
Pump speed
r/min
410
410
410
Average injection quantity
mm3/st.
9
8
10
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
135
135
145
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
R1-1
Boost pressure
kPa
8
8
8
Boost pressure
mmHg
60
60
60
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
R1(10.1)
Boost pressure
kPa
18
14
22
Boost pressure
mmHg
135
105
165
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
1.5
1.2
1.8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerances for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Boost compensator stroke: BCL
(6)Main spring setting
----------
K=12 BCL=1+-0.1mm
----------
----------
K=12 BCL=1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=8deg+-5deg b=20deg+-5deg
----------
----------
a=8deg+-5deg b=20deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
0000001501 TAMPER PROOF
Tamperproofing-equipped boost compensator cover installation procedure
(A) After adjusting the boost compensator, tighten the bolts to remove the heads.
(1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque.
(Tightening torque T = T1 maximum)
(2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads.
(Tightening torque T = T2)
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
----------
T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
----------
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Start By:a. remove timing gear cover1. Time the engine as follows:a. Install Tool (A) in the flywheel housing.b. Remove the cover from the side of the fuel injection pump housing so the timing pin can be installed. Remove the plug from the flywheel housing so the timing bolt can be installed.c. Turn the engine in the direction of engine rotation until Tool (B) can be installed in fuel injection pump housing and located in the groove in the fuel injection pump camshaft, a 3/8" - 16 NC bolt can be installed in the flywheel through the hole in the flywheel housing, and the "C" marks on the crankshaft gear and the camshaft gear are in alignment with each other. 2. Loosen bolt (1) until there is approximately 3.18 mm (.125 in) gap between washer (2) and fuel pump drive gear (3).3. Install Tool (C) as shown, and loosen the fuel pump drive gear from the taper on the fuel injection pump camshaft. Remove Tool (C), the bolt, washer and fuel pump drive gear.4. Remove the bolts and plate (4) that hold idler gear (5) in position. Remove the idler gear. If necessary, remove the bearing from the idler gear with Tool (D) and a press.
Do not turn the crankshaft after camshaft gear (6) has been removed. Turning the crankshaft will cause damage to the valves.
5. Remove the four bolts that hold camshaft gear (6) to the camshaft. Remove the camshaft gear.Install Timing Gears
1. Make an alignment of the "C" marks on crankshaft gear (3) and camshaft gear (4). Install the camshaft gear and the bolts that hold it. Tighten the bolts to a torque of 55 7 N m (41 5 lb ft).2. Install the bearing in idler gear (1) with Tool (A). The end of the bearing must be 1.52 mm (.060 in) below the face of the gear hub after installation.3. Be sure the oil hole in the shaft for idler gear (1) is open. Put idler gear (1) and plate (2) in position on the shaft. Install the bolts that hold them. 4. Make sure Tool (C) is in position in the groove of the fuel injection pump camshaft.5. Put fuel injection pump drive gear (5) in position on the fuel injection pump camshaft. Put washer (6) in position on the gear with the largest diameter toward the front of the engine. Install bolt (7), and tighten it to a torque of 7 N m (5 lb ft). Make sure bolt (7) does not turn while the flywheel is being turned.6. Remove the timing bolt from the flywheel, and use Tool (B) to turn the flywheel in the opposite direction of engine rotation. Turn the flywheel until the "C" mark on the crankshaft gear moves 30°.7. Turn the flywheel in the direction of engine rotation until the timing bolt can be installed in the flywheel and the "C" marks are in alignment. This will remove all of the backlash from the timing gears.8.
Do not turn the crankshaft after camshaft gear (6) has been removed. Turning the crankshaft will cause damage to the valves.
5. Remove the four bolts that hold camshaft gear (6) to the camshaft. Remove the camshaft gear.Install Timing Gears
1. Make an alignment of the "C" marks on crankshaft gear (3) and camshaft gear (4). Install the camshaft gear and the bolts that hold it. Tighten the bolts to a torque of 55 7 N m (41 5 lb ft).2. Install the bearing in idler gear (1) with Tool (A). The end of the bearing must be 1.52 mm (.060 in) below the face of the gear hub after installation.3. Be sure the oil hole in the shaft for idler gear (1) is open. Put idler gear (1) and plate (2) in position on the shaft. Install the bolts that hold them. 4. Make sure Tool (C) is in position in the groove of the fuel injection pump camshaft.5. Put fuel injection pump drive gear (5) in position on the fuel injection pump camshaft. Put washer (6) in position on the gear with the largest diameter toward the front of the engine. Install bolt (7), and tighten it to a torque of 7 N m (5 lb ft). Make sure bolt (7) does not turn while the flywheel is being turned.6. Remove the timing bolt from the flywheel, and use Tool (B) to turn the flywheel in the opposite direction of engine rotation. Turn the flywheel until the "C" mark on the crankshaft gear moves 30°.7. Turn the flywheel in the direction of engine rotation until the timing bolt can be installed in the flywheel and the "C" marks are in alignment. This will remove all of the backlash from the timing gears.8.