Information injection-pump assembly
ZEXEL
101603-2490
1016032490
HINO
220205200A
220205200a
Rating:
Service parts 101603-2490 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-3111A
12.
Open Pre:MPa(Kqf/cm2)
17.7{180}/21.6{220}
14.
NOZZLE
Include in #1:
101603-2490
as INJECTION-PUMP ASSEMBLY
Include in #2:
104749-6391
as _
Cross reference number
ZEXEL
101603-2490
1016032490
HINO
220205200A
220205200a
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
800
800
800
Average injection quantity
mm3/st.
110
108.5
111.5
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
66.7
66.7
Boost pressure
mmHg
500
500
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8
7
9
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
E
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
140
150
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
9.1
Boost pressure
kPa
37.3
36
38.6
Boost pressure
mmHg
280
270
290
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
10.1
Boost pressure
kPa
56
52
60
Boost pressure
mmHg
420
390
450
Timer adjustment
Pump speed
r/min
1150--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1100
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
6
5.7
6.3
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)RACK LIMIT
(4)Set idle sub-spring
(5)Main spring setting
(6)Boost compensator stroke: BCL
----------
K=10 BCL=1+-0.1mm
----------
----------
K=10 BCL=1+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=18deg+-5deg b=34deg+-5deg
----------
----------
a=18deg+-5deg b=34deg+-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)
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 flywheelb. remove crankshaft rear seal and wear sleeve **Remove the crankshaft rear seal and wear sleeve only if the engine is equipped with the later design seal. The later design seal can be identified by the rotation marks on the seal.
Some flywheel housings will have more bolts holding the flywheel housing to the cylinder block.
1. If the engine is equipped with an electric starting motor, remove the electric starting motor from the flywheel housing.2. Remove the bolts that hold the oil pan plate to the flywheel housing. Loosen the bolts that hold the oil pan plate to the cylinder block.3. Install spacers between the oil pan plate and the cylinder block to hold the oil pan plate away from the flywheel housing.
3306 Engine Shown4. On 3306 Engines, remove turbocharger oil drain pipe (1).5. Install Tool (A) on the flywheel housing as shown, and fasten a hoist to it.6. Remove all bolts (2) and the flywheel housing from the engine. The weight of the flywheel housing is 37 kg (82 lb).Install Flywheel Housing
3306 Engine Shown1. Install Tool (A) on the flywheel housing. Fasten a hoist to the flywheel housing. 2. Put the gasket and flywheel housing in position on the engine. Install bolts (2) that hold it. Tighten the bolts to a torque of 100 14 N m (74 10 lb ft) as shown.3. Remove Tool (A) from the flywheel housing.4. On 3306 Engines, install turbocharger oil drain line (1).5. Cut the bottom of the flywheel housing gasket off even with the cylinder block and flywheel housing. Put 3S6252 RTV Silicone Adhesive/Sealant on the bottom of the gasket where it makes contact with the oil pan plate gasket.6. Remove the spacers from between the oil pan plate and the cylinder block. Install the bolts that hold the oil pan plate to the flywheel housing. Tighten the bolts that hold the oil pan plate to the cylinder block.7. If the engine is equipped with an electric starting motor, install it on the flywheel housing.End By:a. install crankshaft rear seal and wear sleeveb. install flywheel
Some flywheel housings will have more bolts holding the flywheel housing to the cylinder block.
1. If the engine is equipped with an electric starting motor, remove the electric starting motor from the flywheel housing.2. Remove the bolts that hold the oil pan plate to the flywheel housing. Loosen the bolts that hold the oil pan plate to the cylinder block.3. Install spacers between the oil pan plate and the cylinder block to hold the oil pan plate away from the flywheel housing.
3306 Engine Shown4. On 3306 Engines, remove turbocharger oil drain pipe (1).5. Install Tool (A) on the flywheel housing as shown, and fasten a hoist to it.6. Remove all bolts (2) and the flywheel housing from the engine. The weight of the flywheel housing is 37 kg (82 lb).Install Flywheel Housing
3306 Engine Shown1. Install Tool (A) on the flywheel housing. Fasten a hoist to the flywheel housing. 2. Put the gasket and flywheel housing in position on the engine. Install bolts (2) that hold it. Tighten the bolts to a torque of 100 14 N m (74 10 lb ft) as shown.3. Remove Tool (A) from the flywheel housing.4. On 3306 Engines, install turbocharger oil drain line (1).5. Cut the bottom of the flywheel housing gasket off even with the cylinder block and flywheel housing. Put 3S6252 RTV Silicone Adhesive/Sealant on the bottom of the gasket where it makes contact with the oil pan plate gasket.6. Remove the spacers from between the oil pan plate and the cylinder block. Install the bolts that hold the oil pan plate to the flywheel housing. Tighten the bolts that hold the oil pan plate to the cylinder block.7. If the engine is equipped with an electric starting motor, install it on the flywheel housing.End By:a. install crankshaft rear seal and wear sleeveb. install flywheel