101601-2590 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016012590 220003491a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101601-2590 1016012590

HINO 220003491A 220003491a

Service parts 101601-2590 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP

3. GOVERNOR 105482-7120

4. SUPPLY PUMP 105210-4350

5. AUTOM. ADVANCE MECHANIS 105634-0100

6. COUPLING PLATE 105662-0550

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4303

11. Nozzle and Holder 23600-1171

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-4341

14. NOZZLE

105015-3850

15. NOZZLE SET

Include in #1:

101601-2590 as INJECTION-PUMP ASSEMBLY

101692-3500 as _

Cross reference number

ZEXEL 101601-2590 1016012590

HINO 220003491A 220003491a

Zexel num

Bosch num

Firm num

Name

101601-2590
101601-2592

220003491A HINO

INJECTION-PUMP ASSEMBLY
EL100 *

Calibration Data:

Adjustment conditions

Test oil
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

Overflow valve 134424-0620

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
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

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

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 D

Rack position 4.9

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 6 4.5 7.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_04

Adjusting point E

Rack position 11.4+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 78 78 98

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1200

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 1.4 0.9 1.9

Timer adjustment_03

Pump speed r/min 1450

Advance angle deg. 4.5 4.2 4.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Excess fuel setting for starting: SXL
----------
DL=4-0.5mm SXL=9.7+0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=12deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=18deg+-5deg b=27deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=21deg+-5deg b=69deg+-5deg

0000001501 MICRO SWITCH

Switch adjustment Adjust the bolt so that the lower lever position is obtained when the switch is turned ON. (1)Speed N1 (2)Rack position Ra
----------
N1=350+25r/min Ra=4.9mm
----------