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Information injection-pump assembly
ZEXEL
101401-2091
1014012091
HINO
220005510A
220005510a
Service parts 101401-2091 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
236001880A
12.
Open Pre:MPa(Kqf/cm2)
21.6(220)
15.
NOZZLE SET
Cross reference number
ZEXEL
101401-2091
1014012091
HINO
220005510A
220005510a
Zexel num
Bosch num
Firm num
Name
101401-2091
220005510A HINO
INJECTION-PUMP ASSEMBLY
W04C-T * K
W04C-T * K
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
1-3-4-2
Pre-stroke
mm
3.2
3.17
3.23
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
Cyl.1-2 deg. 270 269.75 270.25
Injection quantity adjustment
Adjusting point
-
Rack position
10.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
84.2
82.2
86.2
Max. variation between cylinders
%
0
-3
3
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
8+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8.6
7.1
10.1
Max. variation between cylinders
%
0
-15
15
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(10.8)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
84.2
83.2
85.2
Basic
*
Fixing the lever
*
Boost pressure
kPa
25.3
25.3
Boost pressure
mmHg
190
190
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.5
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
86.2
82.2
90.2
Fixing the lever
*
Boost pressure
kPa
25.3
25.3
Boost pressure
mmHg
190
190
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.25
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
85.2
81.2
89.2
Fixing the lever
*
Boost pressure
kPa
25.3
25.3
Boost pressure
mmHg
190
190
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1-0.5
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
65.2
61.2
69.2
Fixing the lever
*
Boost pressure
kPa
25.3
25.3
Boost pressure
mmHg
190
190
Injection quantity adjustment_07
Adjusting point
E
Rack position
-
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
54.6
50.6
58.6
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_08
Adjusting point
I
Rack position
14.3+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
106
106
116
Fixing the lever
*
Rack limit
*
Injection quantity adjustment_09
Adjusting point
K
Rack position
R1-1.8
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
41.4
37.4
45.4
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
650
650
650
Rack position
R1-1.8
Boost pressure
kPa
2
2
4.7
Boost pressure
mmHg
15
15
35
Boost compensator adjustment_02
Pump speed
r/min
650
650
650
Rack position
R1-0.5
Boost pressure
kPa
12
12
12
Boost pressure
mmHg
90
90
90
Timer adjustment
Pump speed
r/min
1300+50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1600
Advance angle
deg.
2.5
2.2
2.8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
(3)Boost compensator stroke: BCL
----------
T1=C04 BCL=1.3+-0.1mm
----------
----------
T1=C04 BCL=1.3+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=34deg+-5deg b=42deg+-3deg
----------
----------
a=34deg+-5deg b=42deg+-3deg
Stop lever angle
N:Engine normal (pump normal)
S:Engine stop
(1)Set the stopper screw.
(2)(Apply red paint after setting.)
----------
----------
a=20deg+-5deg b=(28deg)+-5deg
----------
----------
a=20deg+-5deg b=(28deg)+-5deg
0000001501 ACTUATOR
(a) Screw
(B) Nut
(c) set bolt
(d) control lever
1. Actuator adjustment procedure
(1)Position the control lever (d) in the idling position.
(2)Set the clearance between the control lever (d) and the set bolt (c) to approx. L1.
(3)Loosen the nut (b) and fully tighten the screw (a).
(4)Set the pump speed at N1and measure the rack position when negative pressure P1 is applied to the actuator.
(5)Loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1.
(6)Confirm that control lever (d) returns to the idling position at actuator negative pressure 0.
(7)Repeat procedures (4) to (6) several times and confirm that the control lever (d) moves smoothly.
----------
L1=2mm R1=9.1~9.4mm P1=66.7kPa(500mmHg) N1=300r/min N2=300r/min
----------
----------
L1=2mm R1=9.1~9.4mm P1=66.7kPa(500mmHg) N1=300r/min N2=300r/min
----------
0000001601 TAMPER PROOF
1. Method for setting tamperproof proofing
(1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to Ra.
(2)At pump speed N1, push in the screw (A) until the rack position is Rb.
(3)Temporarily caulk using the tip of a screwdriver
(4)Confirm that the rack at that time is at Rc.
(5)Lock using setscrew (B). (Tightening torque = T)
(6)Next, coat (C) with adhesive and then pressfit.
(7)Then, readjust the full rack position using the load lever.
----------
N1=1600r/min Ra=(0.4)mm Rb=R1(10.8)mm Rc=R1(10.8)mm
----------
T=4.9~6.9N-m(0.5~0.7Kgf-m)
----------
N1=1600r/min Ra=(0.4)mm Rb=R1(10.8)mm Rc=R1(10.8)mm
----------
T=4.9~6.9N-m(0.5~0.7Kgf-m)
0000001701 LEVER
(N) Engine normal (pump normal)
(S) Engine stop
(A) stopper screw
(B) Stop direction (perpendicular)
Stop lever adjusting procedure
(1)After completing adjustment, confirm that the engine's normal lever angle (pump's normal lever) is within the specifications in the figure above.
(2)With the speed lever at Full and the pump speed at Na (specified speed), temporarily set the stopper screw (A) at the rack position Ra.
(3)Turn the stopper screw (A) Rb in the stop direction (Nb turns) and set it. Measure the rack position. (Rack position = approx. Rc)
(4)After setting, confirm non-injection with the speed lever at idle and pump speed at Nc.
(5)After adjustment, apply red paint.
----------
Na=- Ra=5.3mm Rb=1.5mm Nb=1.5 Rc=3.3mm Nc=300r/min
----------
ra=37mm a=20deg+-5deg b=(28deg)+-5deg
----------
Na=- Ra=5.3mm Rb=1.5mm Nb=1.5 Rc=3.3mm Nc=300r/min
----------
ra=37mm a=20deg+-5deg b=(28deg)+-5deg
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(70deg)
----------
----------
a=(70deg)
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101401-2091
220005510A
INJECTION-PUMP ASSEMBLY
W04C-T
W04C-T