Information injection-pump assembly
ZEXEL
101601-5211
1016015211
HINO
220005180A
220005180a
Rating:
Cross reference number
ZEXEL
101601-5211
1016015211
HINO
220005180A
220005180a
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
3.07
3.13
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
-
Rack position
9.6
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
70
69
71
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
7.2+-0.1
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
*
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_03
Adjusting point
A
Rack position
R1(9.6)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
70
69
71
Basic
*
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1250--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1200
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1450
Advance angle
deg.
4
3.5
4.5
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)RACK LIMIT
----------
T1=B97
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T1=B97
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Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=33deg+-5deg b=(45deg)+-3deg
----------
----------
a=33deg+-5deg b=(45deg)+-3deg
Stop lever angle
N:Engine normal (pump normal)
S:Engine stop
(1)Set the stopper screw. (After setting, apply red paint.)
----------
----------
a=0deg+-5deg b=(29deg)+-5deg
----------
----------
a=0deg+-5deg b=(29deg)+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(60deg)
----------
----------
a=(60deg)
Information:
Stand By:a. remove engineb. remove timing gear coverc. remove flywheel housingd. remove pistons and connecting rods
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Turn the crankshaft until the timing mark (C) on the crankshaft gear (1) is in alignment with the timing mark (C) on camshaft gear (2).2. Make a mark on the teeth of the fuel pump drive gear and the idler gear in their engaged position at location (X). Make a mark on the engaged teeth of idler gear and camshaft gear at location (Y). This will give assistance in the correct timing of the camshaft for the fuel injection pump during crankshaft installation. 3. Fasten a hoist to the crankshaft.4. Remove the caps for the main bearings.5. Remove the crankshaft. Weight of the crankshaft is 95 kg (210 lb.).6. Remove the main bearings from the main bearing caps. Remove the crankshaft main bearings from the cylinder block. 7. Use tool (A) to remove the crankshaft gear and the oil seal wear sleeve.Install Crankshaft
Install the bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and main bearing caps.
1. Clean the bearing surfaces in the cylinder block. Install the upper halves of the main bearings in the block.2. Heat the crankshaft gear to a maximum temperature of 315° C (600° F). Install the gear on the crankshaft. Fasten a hoist to the crankshaft and put the crankshaft in position in the cylinder block with all timing marks in alignment.3. Clean the bearing surfaces of the main bearing caps. Install the lower halves of the main bearings in the caps. When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position to check clearances. 4. Check the main bearing clearances with Plastigage (B) as follows:a. Put a piece of Plastigage (B) in position as shown.
Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.
Do not turn the crankshaft when Plastigage (B) is in position.b. Install the main bearing caps. Put 2P2506 Thread Lubricant on the bolt threads and the face of the washers and install the bolts. Tighten the bolts to a
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
1. Turn the crankshaft until the timing mark (C) on the crankshaft gear (1) is in alignment with the timing mark (C) on camshaft gear (2).2. Make a mark on the teeth of the fuel pump drive gear and the idler gear in their engaged position at location (X). Make a mark on the engaged teeth of idler gear and camshaft gear at location (Y). This will give assistance in the correct timing of the camshaft for the fuel injection pump during crankshaft installation. 3. Fasten a hoist to the crankshaft.4. Remove the caps for the main bearings.5. Remove the crankshaft. Weight of the crankshaft is 95 kg (210 lb.).6. Remove the main bearings from the main bearing caps. Remove the crankshaft main bearings from the cylinder block. 7. Use tool (A) to remove the crankshaft gear and the oil seal wear sleeve.Install Crankshaft
Install the bearings dry when the clearance checks are made. Put clean engine oil on the main bearings for final assembly.
Make sure the upper and lower halves of the main bearings are installed so the bearing tabs fit into the notch in the cylinder block and main bearing caps.
1. Clean the bearing surfaces in the cylinder block. Install the upper halves of the main bearings in the block.2. Heat the crankshaft gear to a maximum temperature of 315° C (600° F). Install the gear on the crankshaft. Fasten a hoist to the crankshaft and put the crankshaft in position in the cylinder block with all timing marks in alignment.3. Clean the bearing surfaces of the main bearing caps. Install the lower halves of the main bearings in the caps. When the bearing clearance is checked and the engine is in a vertical position, such as in the vehicle, the crankshaft will have to be lifted up and held against the upper halves of the main bearings to get a correct measurement with the Plastigage. The Plastigage will not hold the weight of the crankshaft and give a correct indication. If the engine is in a horizontal position, it is not necessary to hold the crankshaft up. Do not turn the crankshaft when the Plastigage is in position to check clearances. 4. Check the main bearing clearances with Plastigage (B) as follows:a. Put a piece of Plastigage (B) in position as shown.
Make sure the part number on the main bearing cap is toward the front of the engine and the number on the main bearing cap is the same as the number on the cylinder block on the left side of each main bearing cap.
Do not turn the crankshaft when Plastigage (B) is in position.b. Install the main bearing caps. Put 2P2506 Thread Lubricant on the bolt threads and the face of the washers and install the bolts. Tighten the bolts to a