Information
ZEXEL
101601-2310
1016012310
HINO
220001560C
220001560c
Rating:
Service parts 101601-2310 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-1152
12.
Open Pre:MPa(Kqf/cm2)
21.6{220}
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-2310
1016012310
HINO
220001560C
220001560c
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
134424-0620
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
3.1
3.05
3.15
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
B
Rack position
6.8
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
68.6
67.6
69.6
Max. variation between cylinders
%
0
-3.5
3.5
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.8
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
68.5
67
70
Max. variation between cylinders
%
0
-5
5
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
D
Rack position
5.2+-0.5
Pump speed
r/min
375
375
375
Average injection quantity
mm3/st.
8
7
9
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
Adjust only variation between cylinders; adjust governor according to governor specifications.
Injection quantity adjustment_04
Adjusting point
E
Rack position
9.8+0.2
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
70
70
90
Fixing the lever
*
Timer adjustment
Pump speed
r/min
800++
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1000
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1300
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)RACK LIMIT
(3)Set the 2nd idle sub spring.
----------
DL=5.7-0.2mm
----------
----------
DL=5.7-0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=10deg+-5deg
----------
----------
a=10deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=24deg+-5deg b=26deg+-3deg
----------
----------
a=24deg+-5deg b=26deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=21deg+-5deg b=59deg+-5deg
----------
----------
a=21deg+-5deg b=59deg+-5deg
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=375-25r/min Ra=5.5mm
----------
----------
N1=375-25r/min Ra=5.5mm
----------
Information:
Use 5P3519 Piston Ring Groove Gauge to check top and intermediate ring grooves with straight sides. For instructions on the use of the gauge, see the GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER LINERS, Form No. SEBF8001.1P435 Piston Assembly
Maximum permissible clearance between ring and groove (all rings) ... .014 in.(0.36 mm)(1) Clearance between top ring and groove ... .0057 to .0071 in.(0.145 to 0.180 mm)(2) Clearance between center ring and groove ... .0030 to .0048 in.(0.076 to 0.122 mm)(3) Clearance between oil ring and groove ... .0015 to .0030 in.(0.038 to 0.076 mm)(4) Bore in piston for pin ... 2.0005 .0002 in.(50.813 0.005 mm) Clearance between pin and bore in piston (new) ... .0003 to .0010 in.(0.008 to 0.025 mm)Maximum permissible clearance between piston pin and bore in piston (worn) ... .002 in.(0.05 mm)Clearance between ends of piston ring, installed in cylinder liner with bore size of ... 5.400 to 5.402 in.(137.16 to 137.21 mm)*(5) Top ring ... .019 to .029 in.(0.48 to 0.74 mm)(6) Center ring ... .019 to .029 in.(0.48 to 0.74 mm)(7) Oil ring ... .015 to .025 in.(0.38 to 0.64 mm) ... .003 in.(0.08 mm)*Increase in clearance between ends of piston rings for each .001 in. (0.03 mm) increase in size of bore of the cylinder liner 9S2266 Piston Assembly
Maximum permissible clearance between ring and groove (all rings) ... .006 in.(0.15 mm)(1) Clearance between top ring and groove ... .0055 to .0073 in.(0.140 to 0.185 mm)(2) Clearance between center ring and groove ... .0030 to .0048 in.(0.076 to 0.122 mm)(3) Clearance between oil ring and groove ... .0015 to .0030 in.(0.038 to 0.076 mm)(4) Bore in piston for pin ... 2.0005 .0002 in.(50.813 0.005 mm) Clearance between pin and bore in piston ... .0003 to .0010 in.(0.008 to 0.025 mm)Maximum permissible clearance between piston pin and bore in piston ... .002 in.(0.05 mm)Clearance between ends of piston ring, installed in cylinder liner with bore size of ... 5.400 to 5.402 in.(137.16 to 173.21 mm)*(5) Top ring ... .021 to .027 in.(0.53 to 0.69 mm)(6) Center ring ... .019 to .029 in.(0.48 to 0.74 mm)(7) Oil ring ... .015 to .025 in.(0.38 to 0.64 mm) ... .003 in.(0.08 mm)*Increase in clearance between ends of piston rings for each .001 in. (0.03 mm) increase in size of bore of the cylinder liner 9L6054 And 9N2875 Piston Assemblies
Make reference to GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER LINERS, Form No. SEBF8001. (4) Bore in piston for pin ... 2.0005 .0002 in.(50.81 0.005 mm) Clearance between pin and bore in piston ... .0007 .0004 in.(0.018 0.010 mm)Maximum permissible clearance (worn) ... .002 in.(0.05 mm)Pin diameter ... 1.9998 .0002 in.(50.795 0.005 mm) When installed in the engine, the "V" mark on top of the piston must be in alignment with the "V"
Maximum permissible clearance between ring and groove (all rings) ... .014 in.(0.36 mm)(1) Clearance between top ring and groove ... .0057 to .0071 in.(0.145 to 0.180 mm)(2) Clearance between center ring and groove ... .0030 to .0048 in.(0.076 to 0.122 mm)(3) Clearance between oil ring and groove ... .0015 to .0030 in.(0.038 to 0.076 mm)(4) Bore in piston for pin ... 2.0005 .0002 in.(50.813 0.005 mm) Clearance between pin and bore in piston (new) ... .0003 to .0010 in.(0.008 to 0.025 mm)Maximum permissible clearance between piston pin and bore in piston (worn) ... .002 in.(0.05 mm)Clearance between ends of piston ring, installed in cylinder liner with bore size of ... 5.400 to 5.402 in.(137.16 to 137.21 mm)*(5) Top ring ... .019 to .029 in.(0.48 to 0.74 mm)(6) Center ring ... .019 to .029 in.(0.48 to 0.74 mm)(7) Oil ring ... .015 to .025 in.(0.38 to 0.64 mm) ... .003 in.(0.08 mm)*Increase in clearance between ends of piston rings for each .001 in. (0.03 mm) increase in size of bore of the cylinder liner 9S2266 Piston Assembly
Maximum permissible clearance between ring and groove (all rings) ... .006 in.(0.15 mm)(1) Clearance between top ring and groove ... .0055 to .0073 in.(0.140 to 0.185 mm)(2) Clearance between center ring and groove ... .0030 to .0048 in.(0.076 to 0.122 mm)(3) Clearance between oil ring and groove ... .0015 to .0030 in.(0.038 to 0.076 mm)(4) Bore in piston for pin ... 2.0005 .0002 in.(50.813 0.005 mm) Clearance between pin and bore in piston ... .0003 to .0010 in.(0.008 to 0.025 mm)Maximum permissible clearance between piston pin and bore in piston ... .002 in.(0.05 mm)Clearance between ends of piston ring, installed in cylinder liner with bore size of ... 5.400 to 5.402 in.(137.16 to 173.21 mm)*(5) Top ring ... .021 to .027 in.(0.53 to 0.69 mm)(6) Center ring ... .019 to .029 in.(0.48 to 0.74 mm)(7) Oil ring ... .015 to .025 in.(0.38 to 0.64 mm) ... .003 in.(0.08 mm)*Increase in clearance between ends of piston rings for each .001 in. (0.03 mm) increase in size of bore of the cylinder liner 9L6054 And 9N2875 Piston Assemblies
Make reference to GUIDELINE FOR REUSABLE PARTS; PISTONS AND CYLINDER LINERS, Form No. SEBF8001. (4) Bore in piston for pin ... 2.0005 .0002 in.(50.81 0.005 mm) Clearance between pin and bore in piston ... .0007 .0004 in.(0.018 0.010 mm)Maximum permissible clearance (worn) ... .002 in.(0.05 mm)Pin diameter ... 1.9998 .0002 in.(50.795 0.005 mm) When installed in the engine, the "V" mark on top of the piston must be in alignment with the "V"