Information injection-pump assembly
ZEXEL
101601-5340
1016015340
HINO
220005720A
220005720a
Rating:
Service parts 101601-5340 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
18.1(185)
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-5340
1016015340
HINO
220005720A
220005720a
Zexel num
Bosch num
Firm num
Name
101601-5340
220005720A HINO
INJECTION-PUMP ASSEMBLY
EL100 * K
EL100 * 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
131424-4220
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
4.8
4.9
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
9
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
86.7
85.1
88.3
Max. variation between cylinders
%
0
-2
2
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
C
Rack position
9.7
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
100.7
98.1
103.3
Max. variation between cylinders
%
0
-3
3
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
-
Rack position
5.1+-0.5
Pump speed
r/min
250
250
250
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.
Injection quantity adjustment_04
Adjusting point
E
Rack position
10+-0.5
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
101
99.4
102.6
Fixing the rack
*
Timer adjustment
Pump speed
r/min
1150+-50
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1300
Advance angle
deg.
1.9
1.4
2.4
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)RACK LIMIT
(2)Damper spring setting: DL
----------
DL=4-0.5mm
----------
----------
DL=4-0.5mm
----------
Speed control lever angle
F:Full speed
----------
----------
a=11deg+-5deg
----------
----------
a=11deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
----------
----------
a=18deg+-5deg b=27deg+-3deg
----------
----------
a=18deg+-5deg b=27deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=21deg+-5deg b=69deg+-5deg
----------
----------
a=21deg+-5deg b=69deg+-5deg
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Engine Crankshaft Will Not Turn
Possible Causes/Corrections
Low Or No Battery VoltageCheck battery voltage. If battery voltage is less than 8 volts for a 12 volt system, or 16 volts for a 24 volt system, put a charge to the battery. If battery will not hold a charge, load test the battery as shown in the Electrical System of the Testing and Adjusting Section of this Service Manual. Defective Switch, Defective Wiring Or Connection In Swith CircuitWith ignition switch in START position, check voltage at switch connection on starter solenoid. If there is no voltage, or if the voltage is low at this connection, check wiring, connections, ignition switch, and magnetic switch (if used). Defective Cable Or Connection; Battery To StarterWith ignition switch in the START position, check voltage at connection of battery cable to starter. If there is no voltage, or if the voltage is low at this connection and there is good voltage at the battery, check for defective cable or connection between the battery and the starter. Defective Starter SolenoidRemove and repair a solenoid which does not work when voltage is correct at both the battery and ignition switch connections. Defective Starter MotorIf the solenoid works and the starter motor does not turn the crankshaft, the starter motor is defective. Before removing the starter motor, turn the crankshaft by hand to be sure a mechanical failure inside the engine, transmission, or power take-off is not preventing the crankshaft from turning. If crankshaft turns freely by hand, engage the starter motor again. If the starter motor still will not work, remove the starter motor and repair it, or install a new starter motor. Transmission Or Power Take-off (if so equipped) Problem Prevents Crankshaft From TurningIf crankshaft can not be turned by hand, disconnect the transmission and power take-off. If crankshaft will now turn, find the cause of the problem in the transmission or power take-off and make necessary corrections. Inside Problem Prevents Engine Crankshaft From TurningIf the crankshaft can not be turned after disconnecting the transmission and power take-off, remove the fuel nozzles and check for fluid in the cylinders while turning the crankshaft. If fluid in the cylinders is not the problem, the engine must be disassembled to check for other inside problems. Some of these inside problems are bearing seizure, piston seizure, and valves making contact with pistons.Engine Crankshaft Turns Too Slowly
Possible Causes/Corrections
Low Battery VoltageCheck battery voltage. If battery voltage is less than 8 volts for a 12 volt system, or 16 volts for a 24 volt system, put a charge to the battery. If the battery will not hold a charge, load test the battery as shown in the Electrical System of the Testing and Adjusting Section of this Service Manual. Defective Cable Or Connection; Battery To StarterWith switch in START position, check voltage at battery cable connection to starter. If voltage is low at this connection and there is good voltage at the battery, check for defective cable or connection between the battery and
Possible Causes/Corrections
Low Or No Battery VoltageCheck battery voltage. If battery voltage is less than 8 volts for a 12 volt system, or 16 volts for a 24 volt system, put a charge to the battery. If battery will not hold a charge, load test the battery as shown in the Electrical System of the Testing and Adjusting Section of this Service Manual. Defective Switch, Defective Wiring Or Connection In Swith CircuitWith ignition switch in START position, check voltage at switch connection on starter solenoid. If there is no voltage, or if the voltage is low at this connection, check wiring, connections, ignition switch, and magnetic switch (if used). Defective Cable Or Connection; Battery To StarterWith ignition switch in the START position, check voltage at connection of battery cable to starter. If there is no voltage, or if the voltage is low at this connection and there is good voltage at the battery, check for defective cable or connection between the battery and the starter. Defective Starter SolenoidRemove and repair a solenoid which does not work when voltage is correct at both the battery and ignition switch connections. Defective Starter MotorIf the solenoid works and the starter motor does not turn the crankshaft, the starter motor is defective. Before removing the starter motor, turn the crankshaft by hand to be sure a mechanical failure inside the engine, transmission, or power take-off is not preventing the crankshaft from turning. If crankshaft turns freely by hand, engage the starter motor again. If the starter motor still will not work, remove the starter motor and repair it, or install a new starter motor. Transmission Or Power Take-off (if so equipped) Problem Prevents Crankshaft From TurningIf crankshaft can not be turned by hand, disconnect the transmission and power take-off. If crankshaft will now turn, find the cause of the problem in the transmission or power take-off and make necessary corrections. Inside Problem Prevents Engine Crankshaft From TurningIf the crankshaft can not be turned after disconnecting the transmission and power take-off, remove the fuel nozzles and check for fluid in the cylinders while turning the crankshaft. If fluid in the cylinders is not the problem, the engine must be disassembled to check for other inside problems. Some of these inside problems are bearing seizure, piston seizure, and valves making contact with pistons.Engine Crankshaft Turns Too Slowly
Possible Causes/Corrections
Low Battery VoltageCheck battery voltage. If battery voltage is less than 8 volts for a 12 volt system, or 16 volts for a 24 volt system, put a charge to the battery. If the battery will not hold a charge, load test the battery as shown in the Electrical System of the Testing and Adjusting Section of this Service Manual. Defective Cable Or Connection; Battery To StarterWith switch in START position, check voltage at battery cable connection to starter. If voltage is low at this connection and there is good voltage at the battery, check for defective cable or connection between the battery and
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Group cross 101601-5340 ZEXEL
Hino
Hino
Hino
101601-5340
220005720A
INJECTION-PUMP ASSEMBLY
EL100
EL100