101601-5271 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015271 220005610a


101601-5271 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101601-5271 1016015271
HINO 220005610A 220005610a

Service parts 101601-5271 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-9891
3. GOVERNOR 105921-2150
4. SUPPLY PUMP 105220-5140
5. AUTOM. ADVANCE MECHANIS 105676-0221
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:

101601-5271 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-5271 1016015271
HINO 220005610A 220005610a


Zexel num
Bosch num
Firm num
Name
101601-5271 
 
220005610A  HINO
INJECTION-PUMP ASSEMBLY
W06D * 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   8.7
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   46.6 44.6 48.6
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.   8 6.5 9.5
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(8.7)
Pump speed r/min   1000 1000 1000
Average injection quantity mm3/st.   46.6 45.6 47.6
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.3
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   45.2 43.2 47.2
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.2
Pump speed r/min   1300 1300 1300
Average injection quantity mm3/st.   52 50 54
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1-0.15
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   38 36 40
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   I
Rack position   13.5+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   95 95 105
Fixing the lever   *
Rack limit   *
Injection quantity adjustment_08
Adjusting point   E
Rack position   R1+0.35
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   28 24 32
Fixing the lever   *
Timer adjustment
Pump speed r/min   1300+50
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1600
Advance angle deg.   3.5 3.2 3.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-5271
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=A76
----------

Speed control lever angle

Test data 101601-5271
F:Full speed I:Idle (1)- (2)Stopper bolt setting
----------

----------
a=33deg+-3deg b=34deg+-5deg

Stop lever angle

Test data 101601-5271
N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-5deg

0000001501 TAMPER PROOF

Test data 101601-5271
1. Method for setting tamperproof proofing (1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to Ra. (2)At pump speed N1, push in the screw (A) until the rack position is Rb. (3)Temporarily caulk using the tip of a screwdriver (4)Confirm that the rack at that time is at Rc. (5)Lock using setscrew (B). (Tightening torque = T) (6)Next, coat (C) with adhesive and then pressfit. (7)Then, readjust the full rack position using the load lever.
----------
N1=1600r/min Ra=(0.4)mm Rb=R1(8.7)-0.3mm Rc=R1(8.7)-0.3mm
----------
T=4.9~7N-m(0.5~0.7Kgf-m)

Timing setting

Test data 101601-5271
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




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