Information injection-pump assembly
ZEXEL
101651-2200
1016512200
HINO
220001440B
220001440b
Rating:
Service parts 101651-2200 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1430
12.
Open Pre:MPa(Kqf/cm2)
11.8{120}
15.
NOZZLE SET
Include in #1:
101651-2200
as INJECTION-PUMP ASSEMBLY
Cross reference number
ZEXEL
101651-2200
1016512200
HINO
220001440B
220001440b
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
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
1.95
1.9
2
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
12.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
54
53
55
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
12.8
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
56.3
54.8
57.8
Max. variation between cylinders
%
0
-3
3
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
9+-0.5
Pump speed
r/min
225
225
225
Average injection quantity
mm3/st.
15
12.9
17.1
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Timer adjustment
Pump speed
r/min
300+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
600
Advance angle
deg.
1.8
1.3
2.3
Timer adjustment_03
Pump speed
r/min
900
Advance angle
deg.
3.4
2.9
3.9
Timer adjustment_04
Pump speed
r/min
1200
Advance angle
deg.
5.1
4.6
5.6
Timer adjustment_05
Pump speed
r/min
1350
Advance angle
deg.
6
5.5
6.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Adjust with the speed control lever at the Full position
(2)Adjust the load control lever in the full position.
(3)Beginning of damper spring operation: DL
(4)RACK LIMIT: RAL
----------
DL=7.6-0.2mm RAL=14.5+0.5mm
----------
----------
DL=7.6-0.2mm RAL=14.5+0.5mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=15deg
----------
----------
a=15deg
0000000901
F:Full load
I:Idle
S:Stop
----------
----------
a=11deg+-5deg b=8deg+-5deg c=34.5deg+-3deg
----------
----------
a=11deg+-5deg b=8deg+-5deg c=34.5deg+-3deg
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=325-25r/min Ra=9mm
----------
----------
N1=325-25r/min Ra=9mm
----------
Information:
(1) Bore in bearing of idler gear ... 28.600 0.048 mm (1.1260 .0019 in) Diameter of shaft for the idler gear ... 28.512 0.013 mm (1.1225 .0005 in)Clearance between bearing and shaft ... 0.028 to 0.150 mm (.0011 to .0059 in)(2) Clearance between gear and body of pump ... 0.05 to 0.66 mm (.002 to .026 in)(3) Diameter of shafts for pump ... 22.217 0.005 mm (.8747 .0002 in) Bore in bearings for shafts (2P1785) ... 22.258 0.008 mm (.8763 .0003 in)Bore in bearings for shafts (4W2448) ... 22.286 0.051 mm (.8774 .0020 in)Clearance between shafts and bearings (2P1785) ... 0.028 to 0.053 mm (.0011 to .0021 in)Clearance between shafts and bearings (4W2448) ... 0.025 to 0.127 mm (.0010 to .0050 in)(4) Depth that bearings are installed in pump bodies ... 1.50 0.25 mm (.060 .010 in)(5) Gear. Length of gears ... 50.808 0.025 mm (2.0003 .0010 in) Depth of bore in pump body for gears ... 50.935 0.020 mm (2.0053 .0008 in)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in)(6) Length of gears ... 38.070 0.025mm (1.4988 .0010 in) Depth of bore in pump body for gears ... 38.197 0.020 mm (1.5038 .0008 in)Clearance between end of gears and pump body ... 0.081 to 0.173 mm (.0032 to .0068 in)(7) Distance from the end of the idler shafts to gear faces ... 21.03 0.13 mm (.828 .005 in) Maximum temperature of gear when shrinking in place ... 398° C (750° F)(8) Distance from the end of the drive shaft to gear face ... 38.2 0.13 mm (1.505 .005 in) Maximum temperature of gear when shrinking in place ... 398° C (750° F)(9) Torque for bolt holding drive gear to drive shaft ... 43 7 N m (32 5 lb ft) Install the bearings in the cover and body for the oil pump so the bearing junctions (joints) are in the position shown.(10) Distance dowel extends from body ... 6.0 0.5 mm (.24 .02 in)(11) Shaft assembly. Distance shaft assembly extends from body ... 30.50 0.25 mm (1.200 .010 in) Before running, lubricate pump with oil. Pump must rotate freely by hand.