Information injection-pump assembly
ZEXEL
101601-5233
1016015233
HINO
220005332A
220005332a
Rating:
Service parts 101601-5233 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
236001840A
12.
Open Pre:MPa(Kqf/cm2)
14.7(150)/19.6(200)
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-5233
1016015233
HINO
220005332A
220005332a
Zexel num
Bosch num
Firm num
Name
101601-5233
220005332A HINO
INJECTION-PUMP ASSEMBLY
W06E * K
W06E * 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
131424-5720
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
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.
57.9
55.9
59.9
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
7.8+-0.5
Pump speed
r/min
250
250
250
Average injection quantity
mm3/st.
5.3
3.8
6.8
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(9.6)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
57.9
56.9
58.9
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1(9.6)
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
63.9
59.9
67.9
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.25
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
40.3
36.3
44.3
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1(9.6)
Pump speed
r/min
1200
1200
1200
Average injection quantity
mm3/st.
63.7
59.7
67.7
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
E
Rack position
R1+0.45
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
39.9
35.9
43.9
Fixing the lever
*
Injection quantity adjustment_08
Adjusting point
I
Rack position
14.5+-0.
5
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
108
108
118
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
1330--
Advance angle
deg.
0
0
0
Load
3/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1280
Advance angle
deg.
0.3
Load
3/4
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
4.5
4.2
4.8
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=C02
----------
----------
T1=C02
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=37deg+-5deg b=44deg+-3deg
----------
----------
a=37deg+-5deg b=44deg+-3deg
Stop lever angle
N:Engine normal (pump normal)
S:Engine stop
(1)Set the stopper screw. (After setting, apply red paint.)
----------
----------
a=20deg+-5deg b=(28deg)+-5deg
----------
----------
a=20deg+-5deg b=(28deg)+-5deg
0000001501 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=1750r/min Ra=5.2mm Rb=1.5mm Nb=1.5 Rc=3.2mm Nc=250r/min
----------
ra=37mm a=20deg+-5deg b=(28deg)+-5deg
----------
Na=1750r/min Ra=5.2mm Rb=1.5mm Nb=1.5 Rc=3.2mm Nc=250r/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)
Information:
(1) Thickness of spacer plate ... 8.585 0.025 mm (.3379 .0009 in)Thickness of gasket that is placed between spacer plate and cylinder block ... 0.208 0.025 mm (.0081 .0009 in)Height of liner over spacer plate, under installation pressure ... 0.13 0.08 mm (.005 .003 in)(2) Height of four dowels above top surface of cylinder block:End dowels (Put 7M7456 Bearing Mount Compound on two end dowels at installation) ... 18.5 0.5 mm (.73 .02 in)Middle dowels ... 16.0 0.5 mm (.63 .02 in)(3) Dimension (new) from centerline of crankshaft bearing bore to top of block (top deck) ... 425.45 0.15 mm (16.750 .006 in)Minimum dimension from centerline of crankshaft bearing bore to top of block (top deck) ... 425.02 mm (16.733 in) The flatness across the whole contact surface of the block must be within 0.10 mm (.004 in) and within 0.05 mm (.002 in) for any 177 mm (7.0 in) section of the surface. The surface finish specification is 3.2 micrometers (125 micro-inches) maximum.(4) Bore in block for camshaft bearings ... 76.835 0.018 mm (3.0250 .0007 in) Install bearings with the oil holes in the bearings on the horizontal centerline. Make sure the bearing joint position is above the oil holes.(5) Bore in the block for the main bearings: Standard, original size (new) ... 129.891 0.013 mm (5.1138 .0005 in)0.64 mm (.025 in) larger than original size ... 130.526 0.013 mm (5.1388 .0005 in)(6) Distance from front of rear face of cylinder block to end of dowels ... 19.1 0.05 mm (.75 .02 in)(7) Width of main bearing cap ... 215.900 0.013 mm (8.5000 .0005 in)Width of block for main bearing cap ... 215.900 0.013 mm (8.5000 .0005 in)Clearance between main bearing cap and cylinder block ... 0.025 mm (.0009 in) tight to 0.025 mm (.0009 in) loose
Tightening Procedure For Main Bearings(8) Torque for the bolts that hold the caps for the main bearings: Install the main bearing caps with the marks (arrow) toward the front of the engine. Install each cap in the correct position by putting the number stamped on the bottom of the cap toward the corresponding number cast on left side of the cylinder block at the pan rail.a. Put 2P2506 Thread Lubricant on the threads of the bolts.b. Tighten the bolts first on the bearing tab side of the cap to ... 260 14 N m (190 10 lb ft)c. Tighten the bolts on the opposite side to ... 260 14 N m (190 10 lb ft)d. Put a mark on each bolt and cap.e. Tighten the bolts on the opposite side, from the mark ... 120 5°f. Tighten the bolts on the bearing tab side of the cap, from the mark ... 120 5°(9) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 165.10 0.10
Tightening Procedure For Main Bearings(8) Torque for the bolts that hold the caps for the main bearings: Install the main bearing caps with the marks (arrow) toward the front of the engine. Install each cap in the correct position by putting the number stamped on the bottom of the cap toward the corresponding number cast on left side of the cylinder block at the pan rail.a. Put 2P2506 Thread Lubricant on the threads of the bolts.b. Tighten the bolts first on the bearing tab side of the cap to ... 260 14 N m (190 10 lb ft)c. Tighten the bolts on the opposite side to ... 260 14 N m (190 10 lb ft)d. Put a mark on each bolt and cap.e. Tighten the bolts on the opposite side, from the mark ... 120 5°f. Tighten the bolts on the bearing tab side of the cap, from the mark ... 120 5°(9) Dimension (new) from centerline of crankshaft bearing bore to bottom of block (pan rails) ... 165.10 0.10
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Hino
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Hino
101601-5233
220005332A
INJECTION-PUMP ASSEMBLY
W06E
W06E