Information injection-pump assembly
ZEXEL
101672-2480
1016722480
HINO
220201111A
220201111a
Rating:
Service parts 101672-2480 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
7.
COUPLING PLATE
8.
_
9.
_
10.
NOZZLE AND HOLDER ASSY
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
13.
NOZZLE-HOLDER
15.
NOZZLE SET
Include in #1:
101672-2480
as INJECTION-PUMP ASSEMBLY
Include in #2:
104740-8740
as _
Cross reference number
ZEXEL
101672-2480
1016722480
HINO
220201111A
220201111a
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
2.1
2.05
2.15
Rack position
After adjusting injection quantity. R=A
After adjusting injection quantity. R=A
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
14.3
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
90.5
88.9
92.1
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
11.5
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
62.2
60.4
64
Max. variation between cylinders
%
0
-3
3
Fixing the rack
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
7.8+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
15.8
13.2
18.4
Max. variation between cylinders
%
0
-13
13
Fixing the rack
*
Injection quantity adjustment_04
Adjusting point
D
Rack position
14.8
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
92
88.7
95.3
Max. variation between cylinders
%
0
-4
4
Fixing the rack
*
Injection quantity adjustment_05
Adjusting point
E
Rack position
14.3+-0.
5
Pump speed
r/min
950
950
950
Average injection quantity
mm3/st.
94.5
91.2
97.8
Max. variation between cylinders
%
0
-14
14
Fixing the rack
*
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 CAP: R1
----------
K=10 R1=(17.5)mm
----------
----------
K=10 R1=(17.5)mm
----------
Speed control lever angle
F:Full speed
I:Idle
S:Stop
(1)Stopper bolt setting
----------
----------
a=6deg+-5deg b=32deg+-3deg c=23deg+-5deg
----------
----------
a=6deg+-5deg b=32deg+-3deg c=23deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Normal
----------
----------
a=(19deg) b=(34deg)
----------
----------
a=(19deg) b=(34deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)After adjusting the injection quantity, adjust at rack position aa.
(4)-
----------
aa=14.3mm
----------
a=(40deg)
----------
aa=14.3mm
----------
a=(40deg)
Information:
Illustration 1 g00564355
7W-2743 Electronic Speed Switch (ESS)
(1) Push button for Overspeed Verification
(2) Reset button
(3) Overspeed indicator lamp
(4) Seal screw plug for adjusting the engine overspeed
(5) Seal screw plug for adjusting the crank terminate speed
(6) Seal screw plug for adjusting the oil step pressure speed setting The overspeed calibration can increase the overspeed setting or the overspeed calibration can decrease the overspeed setting in order to shut down the engine when the overspeed verification button is pressed. The overspeed setting is correctly made when the engine is running at 75% of the overspeed setting. The engine then shuts down when the overspeed verification button is pressed.Use the following procedure in order to adjust the overspeed setting.
Remove the lockwire and the seal from seal screw plug (4). Remove seal screw plug (4) from the access hole for the overspeed adjustment screw.
Use a small screwdriver to lightly turn the overspeed adjustment screw in the direction of the "MAX" arrow or the clockwise direction. Turn the screw 20 times. The overspeed adjustment screw will vary the setting of a potentiometer that is inside of the ESS. The overspeed adjustment screw will not cause damage to the potentiometer. Also, the screw can not be removed if the screw is turned in the wrong direction.
Run the engine at 75% of the desired overspeed setting rpm. Refer to the Speed Specification Chart.
While the engine is running at 75% of the overspeed setting rpm, press "VERIFY" button (1). While the button is depressed, slowly turn the overspeed adjustment screw in the opposite direction of the "MAX" arrow or the counterclockwise direction until overspeed indicator lamp (3) is lighted. The engine will shut down if the ESS is connected to the fuel shutoff solenoid (FSOS) and the air shutoff solenoid, if equipped.
In order to reset the ESS, press "RESET" button (2). The air shutoff valve must be reset by hand, if equipped.
Slowly turn the overspeed adjustment screw in the clockwise direction for one turn. Repeat Steps 3, 4, and 5. More adjustment may be necessary in order to gain the correct setting. Turn the overspeed adjustment screw in the clockwise direction in order to increase the overspeed setting. Turn the overspeed adjustment screw in the counterclockwise direction in order to decrease the overspeed setting.
When the overspeed setting is correct, install seal screw plug (4) in the access hole for the overspeed adjustment screw. Tighten the screw to a torque of 0.20 0.03 N m (1.8 .3 lb in). Install the lockwire and the seal if the calibration of the crank termination speed and the oil step speed calibration are also complete.