Information injection-pump assembly
ZEXEL
101601-5713
1016015713
HINO
220006802A
220006802a
Rating:
Service parts 101601-5713 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2133
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101601-5713
1016015713
HINO
220006802A
220006802a
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
131424-8320
Overflow valve opening pressure
kPa
108
88
128
Overflow valve opening pressure
kgf/cm2
1.1
0.9
1.3
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
3.8
3.77
3.83
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
11.5
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
76.1
74.5
77.7
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
9+-0.5
Pump speed
r/min
250
250
250
Each cylinder's injection qty
mm3/st.
15
14
16
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(11.5)
Pump speed
r/min
850
850
850
Average injection quantity
mm3/st.
76.1
75.1
77.1
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.45
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
86.8
82.8
90.8
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.25
Pump speed
r/min
580
580
580
Average injection quantity
mm3/st.
62.8
58.8
66.8
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
D
Rack position
R1+0.45
Pump speed
r/min
1150
1150
1150
Average injection quantity
mm3/st.
85.4
81.4
89.4
Fixing the lever
*
Injection quantity adjustment_07
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
140
140
150
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
925--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
875
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
(920--)
Advance angle
deg.
1
0.7
1.3
Load
4/4
Timer adjustment_04
Pump speed
r/min
1175+50
Advance angle
deg.
1
0.7
1.3
Load
3/4
Timer adjustment_05
Pump speed
r/min
1400+50
Advance angle
deg.
5.5
5.2
5.8
Load
4/4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
----------
T1=H16
----------
----------
T1=H16
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Use the pin at R = aa
(2)Stopper bolt set position 'H'
----------
aa=57mm
----------
a=(40deg)+-3deg b=44deg+-5deg
----------
aa=57mm
----------
a=(40deg)+-3deg b=44deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-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:
The primary fuel filter should be cleaned, and the secondary (main) fuel filter element replaced, as follows: 1. When the fuel pressure gauge (if equipped) indicates low fuel pressure.2. When the engine has a noticable loss of power.3. Every 500 service hours of operation if the engine is not equipped with a fuel pressure gauge.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Disconnect the battery (turn disconnect switch OFF) when changing fuel filters.
Do not fill fuel filters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts.
Close the fuel supply valve at the tank before servicing filters. Open the valve after filter servicing is completed.Cleaning Primary Filter
Use all cleaning solutions with care.
1. Loosen the nut (1) on the filter cover and lower the filter case (3).2. Remove the element (2). Wash the cover and element in clean nonflammable solvent.3. Reinstall the element.4. Install the element and case onto the cover into the case.5. Tighten the bolt.Changing Secondary Filter
1. Unscrew filter element. Throw away the used element. 2. Make certain all of the used element seal is cleaned from the filter base. 3. Coat the seal of the new element with clean diesel fuel.4. Install the filter by hand. When the seal contacts the base, tighten 3/4 turn more.There are rotation marks 90° apart on the filter. Use these as a guide for proper tightening.5. Start the engine and check for leaks. If the engine will not start, prime the fuel system.
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Disconnect the battery (turn disconnect switch OFF) when changing fuel filters.
Do not fill fuel filters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts.
Close the fuel supply valve at the tank before servicing filters. Open the valve after filter servicing is completed.Cleaning Primary Filter
Use all cleaning solutions with care.
1. Loosen the nut (1) on the filter cover and lower the filter case (3).2. Remove the element (2). Wash the cover and element in clean nonflammable solvent.3. Reinstall the element.4. Install the element and case onto the cover into the case.5. Tighten the bolt.Changing Secondary Filter
1. Unscrew filter element. Throw away the used element. 2. Make certain all of the used element seal is cleaned from the filter base. 3. Coat the seal of the new element with clean diesel fuel.4. Install the filter by hand. When the seal contacts the base, tighten 3/4 turn more.There are rotation marks 90° apart on the filter. Use these as a guide for proper tightening.5. Start the engine and check for leaks. If the engine will not start, prime the fuel system.