101601-5202 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015202 220005240a


101601-5202 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101601-5202 1016015202
HINO 220005240A 220005240a

Service parts 101601-5202 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-9931
3. GOVERNOR 105921-1791
4. SUPPLY PUMP 105220-5140
5. AUTOM. ADVANCE MECHANIS 105676-0341
6. COUPLING PLATE
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105110-4292
11. Nozzle and Holder
12. Open Pre:MPa(Kqf/cm2) 21.6(220)
13. NOZZLE-HOLDER 105041-5041
14. NOZZLE 105015-5640
15. NOZZLE SET

Include in #1:

101601-5202 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-5202 1016015202
HINO 220005240A 220005240a


Zexel num
Bosch num
Firm num
Name
101601-5202 
 
220005240A  HINO
INJECTION-PUMP ASSEMBLY
W06E * K

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   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
Injection timing adjustment
Direction of rotation (viewed from drive side)
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
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   -
Rack position   9.2
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   52.4 50.4 54.4
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   8+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   6.8 5.3 8.3
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(9.2)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   52.4 51.4 53.4
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.35
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   50.2 46.2 54.2
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.35
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   36.5 32.5 40.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1-0.1
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   53.1 49.1 57.1
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   E
Rack position   R1+0.2
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   29.2 25.2 33.2
Fixing the lever   *
Injection quantity adjustment_08
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   99 99 109
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1050--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1000
Advance angle deg.   0.3
Timer adjustment_03
Pump speed r/min   1500
Advance angle deg.   4.5 4.2 4.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-5202
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C09
----------

Speed control lever angle

Test data 101601-5202
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=34deg+-5deg b=35deg+-3deg

Stop lever angle

Test data 101601-5202
N:Engine normal (pump normal) S:Engine stop (1)Set the stopper screw. (2)(Apply red paint after setting.)
----------

----------
a=20deg+-5deg b=(28deg)+-5deg

0000001501 LEVER

Test data 101601-5202
(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=1600r/min Ra=5.1mm Rb=1.5mm Nb=1.5 Rc=3.1mm Nc=250r/min
----------
ra=37mm a=20deg+-5deg b=(28deg)+-5deg

Timing setting

Test data 101601-5202
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)




Have questions with 101601-5202?





Group cross 101601-5202 ZEXEL

Hino 

 
 
INJECTION-PUMP ASSEMBLY
W06E
 
 
INJECTION-PUMP ASSEMBLY

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101601-5202  
 
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