Information injection-pump assembly
ZEXEL
101601-2471
1016012471
HINO
220002341A
220002341a
Rating:
Cross reference number
ZEXEL
101601-2471
1016012471
HINO
220002341A
220002341a
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
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
-
Rack position
8.6
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
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
7.3+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
8
7
9
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(8.6)
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
68.6
67.6
69.6
Basic
*
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1000++
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1250
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1400
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)Torque cam stamping: T1
(2)RACK LIMIT: RAL
----------
T1=56 RAL=11.6+0.2mm
----------
----------
T1=56 RAL=11.6+0.2mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=32deg+-5deg b=41deg+-3deg
----------
----------
a=32deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=5deg+-5deg b=40deg+-5deg
----------
----------
a=5deg+-5deg b=40deg+-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=7.3mm
----------
----------
N1=375-25r/min Ra=7.3mm
----------
Information:
2. Remove nuts (1) from studs for main bearing caps (2).3. Remove the main bearing caps.4. Install rubber hose over each of the two studs at both ends of the block. This will protect the crankshaft during removal and installation. 5. Remove the crankshaft from the cylinder block. Weight of crankshaft is 300 lb. (136 kg).6. Remove the main bearings from cylinder block and main bearing caps.
If main bearings are not replaced, old bearings must be installed in same location from which they were removed.
Install Crankshaft
1. Put timing marks (1) on all timing gears in alignment.2. Clean surfaces for bearings in cylinder block. Install upper halves of bearings in block. Put clean oil on bearings.
If replacement of the bearings is not made, old bearings must be installed in same location from which they were removed.
3. Clean bearing caps, and install lower halves of bearings in caps. 4. Fasten a hoist to crankshaft and put it into place in the block with "V" mark on crankshaft gear in alignment with "V" mark on cluster gear. 5. Check bearing clearance with wire (A). Install bearing caps, and tighten both nuts to 75 5 lb. ft. (101.7 6.8 N m). Put a mark across the nuts and studs, and turn nuts an additional 120° from mark. Remove caps and check thickness of wire (A) to find bearing clearance. Bearing clearance must be .0035 to .0066 in. (0.089 to 0.168 mm) for new parts. Maximum permissible clearance for used parts is .010 in. (0.25 mm).6. Put clean oil on threads of studs, face of nuts, and lower halves of bearings. Put bearing caps in their respective positions with number on cap same as number on block, and groove in bearing cap on same side as groove in cylinder block. Install nuts and tighten to 75 5 lb.ft. (101.7 6.8 N m). Put a mark across the nuts and studs, and turn nuts an additional 120° from mark. 7. Use indicator group (B) to check the crankshaft end plate as controlled by lower bearing of No. 7 bearing cap. End play with new parts should be .006 to .018 in. (0.15 to 0.46 mm). Maximum permissible end play with used parts is .035 in. (0.89 mm).end by: a) install flywheel housingb) install front coverc) install pistonsd) install engine and torque divider
If main bearings are not replaced, old bearings must be installed in same location from which they were removed.
Install Crankshaft
1. Put timing marks (1) on all timing gears in alignment.2. Clean surfaces for bearings in cylinder block. Install upper halves of bearings in block. Put clean oil on bearings.
If replacement of the bearings is not made, old bearings must be installed in same location from which they were removed.
3. Clean bearing caps, and install lower halves of bearings in caps. 4. Fasten a hoist to crankshaft and put it into place in the block with "V" mark on crankshaft gear in alignment with "V" mark on cluster gear. 5. Check bearing clearance with wire (A). Install bearing caps, and tighten both nuts to 75 5 lb. ft. (101.7 6.8 N m). Put a mark across the nuts and studs, and turn nuts an additional 120° from mark. Remove caps and check thickness of wire (A) to find bearing clearance. Bearing clearance must be .0035 to .0066 in. (0.089 to 0.168 mm) for new parts. Maximum permissible clearance for used parts is .010 in. (0.25 mm).6. Put clean oil on threads of studs, face of nuts, and lower halves of bearings. Put bearing caps in their respective positions with number on cap same as number on block, and groove in bearing cap on same side as groove in cylinder block. Install nuts and tighten to 75 5 lb.ft. (101.7 6.8 N m). Put a mark across the nuts and studs, and turn nuts an additional 120° from mark. 7. Use indicator group (B) to check the crankshaft end plate as controlled by lower bearing of No. 7 bearing cap. End play with new parts should be .006 to .018 in. (0.15 to 0.46 mm). Maximum permissible end play with used parts is .035 in. (0.89 mm).end by: a) install flywheel housingb) install front coverc) install pistonsd) install engine and torque divider