Information injection-pump assembly
ZEXEL
101601-2710
1016012710
HINO
220201660A
220201660a
Rating:
Cross reference number
ZEXEL
101601-2710
1016012710
HINO
220201660A
220201660a
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 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
4.85
4.82
4.88
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
9.1
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
98.9
96.3
101.5
Max. variation between cylinders
%
0
-3
3
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
8.8
Pump speed
r/min
800
800
800
Average injection quantity
mm3/st.
86.9
85.3
88.5
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
5.2+-0.5
Pump speed
r/min
310
310
310
Average injection quantity
mm3/st.
10
8.5
11.5
Max. variation between cylinders
%
0
-15
15
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.
Timer adjustment
Pump speed
r/min
1150
Advance angle
deg.
0.5
Timer adjustment_02
Pump speed
r/min
-
Advance angle
deg.
4.5
4
5
Remarks
Measure the actual speed, stop
Measure the actual speed, stop
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Beginning of damper spring operation: DL
(2)Set the load lever's stop position so that R = aa (N = 0).
(3)RACK LIMIT: RAL
----------
DL=3.3-0.5mm aa=3.7mm RAL=11.8+0.2mm
----------
----------
DL=3.3-0.5mm aa=3.7mm RAL=11.8+0.2mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=3deg+-5deg
----------
----------
a=3deg+-5deg
0000000901
F:Full load
I:Idle
S:Stop
----------
----------
a=18deg+-5deg b=25deg+-3deg c=22deg+-5deg
----------
----------
a=18deg+-5deg b=25deg+-3deg c=22deg+-5deg
Information:
1. Remove oil supply tube (3), suction bell (2) and suction bell tube (1). 2. Remove bolts (4) that hold the oil pump to the cylinder block and remove oil pump (5).Install Oil Pump
1. Put oil pump (3) in position on the engine. Install the bolts that hold the oil pump to the cylinder block.2. Put clean oil on the O-ring seals of the tubes.3. Install suction bell tube (2), suction bell and oil supply tube (1).end by:a) install oil panDisassemble Oil Pump
start by:a) remove oil pump1. Remove the bolt and washer that hold the gear on the shaft. 2. Use tooling (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve.4. Remove the spring and bypass valve.5. Remove cover (2) from the pump body. 6. Use tooling (B) and remove the bearings from the cover. 7. Remove gears (5) from pump body (4).8. Use tooling (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use tooling (A) to install the bearings in the pump body. Install the bearings so the split in the bearings is 30° 15° from the center line of the oil pump outlet passage (2). 2. Install idler gear (1) and drive gear (3) in the oil pump body. Put clean engine oil on the bearings and the gears. 3. Use tooling (A) and install the bearings in cover (4). Install the bearings so the split in the bearings is 30° 15° from the center line of the bearing bores toward oil pump outlet passage (2).4. Install bypass valve (5), spring (6) and the retainer.5. Install the key on the shaft. 6. Install gear (7) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.end by:a) install oil pump
1. Put oil pump (3) in position on the engine. Install the bolts that hold the oil pump to the cylinder block.2. Put clean oil on the O-ring seals of the tubes.3. Install suction bell tube (2), suction bell and oil supply tube (1).end by:a) install oil panDisassemble Oil Pump
start by:a) remove oil pump1. Remove the bolt and washer that hold the gear on the shaft. 2. Use tooling (A) and remove drive gear (1) from the shaft. Remove the key from the shaft. 3. Remove retainer (3) for the bypass valve.4. Remove the spring and bypass valve.5. Remove cover (2) from the pump body. 6. Use tooling (B) and remove the bearings from the cover. 7. Remove gears (5) from pump body (4).8. Use tooling (B) and remove the bearings from pump body (4).Assemble Oil Pump
1. Use tooling (A) to install the bearings in the pump body. Install the bearings so the split in the bearings is 30° 15° from the center line of the oil pump outlet passage (2). 2. Install idler gear (1) and drive gear (3) in the oil pump body. Put clean engine oil on the bearings and the gears. 3. Use tooling (A) and install the bearings in cover (4). Install the bearings so the split in the bearings is 30° 15° from the center line of the bearing bores toward oil pump outlet passage (2).4. Install bypass valve (5), spring (6) and the retainer.5. Install the key on the shaft. 6. Install gear (7) on the shaft. Install the washer and bolt that hold the gear on the shaft. Be sure the pump turns freely after assembly.end by:a) install oil pump