101601-2350 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016012350 220001561a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-2350 1016012350

HINO 220001561A 220001561a

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Service parts 101601-2350 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-1120

3. GOVERNOR 105480-0240

4. SUPPLY PUMP 105210-4161

5. AUTOM. ADVANCE MECHANIS 105614-3010

6. COUPLING PLATE 105661-0301

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4102

11. Nozzle and Holder 23600-1152

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105031-4281

14. NOZZLE

105015-3680

15. NOZZLE SET

Include in #1:

101601-2350 as INJECTION-PUMP ASSEMBLY

101695-3821 as _

Cross reference number

ZEXEL 101601-2350 1016012350

HINO 220001561A 220001561a

Zexel num

Bosch num

Firm num

Name

101601-2350

220001561A HINO

INJECTION-PUMP ASSEMBLY
EH700 *

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 3.1 3.05 3.15

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 6.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 68.6 67.6 69.6

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.8

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 68.5 67 70

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 5.5+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_04

Adjusting point D

Rack position 9.8+0.2

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 70 70 90

Fixing the lever *

Timer adjustment

Pump speed r/min 800++

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 1300

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min 1500

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)RACK LIMIT (3)Set the 2nd idle sub spring.
----------
DL=5-0.2mm
----------

Speed control lever angle

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

----------
a=10deg+-5deg

0000000901

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

----------
a=24deg+-5deg b=26deg+-3deg

Stop lever angle

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

----------
a=21deg+-5deg b=59deg+-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=375-25r/min Ra=5.5mm
----------

Information:

2. Remove the turbocharger outlet pipe (1) and elbow from the aftercooler and turbocharger as a unit. Cover the openings to keep dirt and foreign material out of the engine.3. Remove breather tube (2) from the engine.4. Disconnect tube assembly (3) from the aftercooler. 5. Remove vent tube (4) from the engine.6. Remove cover (5) from the aftercooler and remove the two O-ring seals from the cover.7. Loosen the clamps on hose (7) and remove tube assembly (6) from the hose and aftercooler. Remove the O-ring seal from the tube assembly. 8. Remove collar (10) and the gasket. Remove the O-ring seal from the collar.9. Remove bolts (9) and remove cover (8). 10. Remove elbow (12) and the gaskets from the engine. Remove aftercooler core assembly (11). Remove the O-ring seals from the core assembly. 11. Remove bolts (13), housing (14) and the gasket from the cylinder head.Install Aftercooler
1. Put the gasket and housing (1) in position on the cylinder head and install the bolts that hold it. 2. Install the gaskets, adapter and elbow (3).3. Put the O-ring seals on core assembly (2) and install core assembly (2) and the gaskets in the housing. 4. Put the O-ring seal on collar (5) and install the gasket and collar in the housing.5. Put the gasket and cover (4) in position on the housing and install the bolts that hold it. 6. Put the O-ring seals on cover (6) and install the gasket and cover. Install vent tube (7).7. Install the O-ring seal on tube assembly (8) and install the gasket and tube assembly (8). 8. Connect tube assembly (11) to the aftercooler housing.9. Install breather tube (10).10. Put the O-ring seals on pipe (9) and install the pipe, elbow and gasket.11. Fill the cooling system with coolant to the correct level.