101601-2810 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016012810 220004240a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-2810 1016012810

HINO 220004240A 220004240a

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Cross reference number

ZEXEL 101601-2810 1016012810

HINO 220004240A 220004240a

Zexel num

Bosch num

Firm num

Name

101601-2810
101601-2811

220004240A HINO

INJECTION-PUMP ASSEMBLY
W06D *

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. 44.4 42.4 46.4

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. 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. 44.4 43.4 45.4

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. 43.5 41.5 45.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.1

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 44.1 42.1 46.1

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.2

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 36.2 34.2 38.2

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 *

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. 5 4.7 5.3

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=93
----------

Speed control lever angle

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

----------
a=32.5deg+-3deg b=34deg+-5deg

Stop lever angle

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

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

Timing setting

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

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

Information:

Fuel system components identified are: 1-Fuel injection nozzles. 2-Fuel lines. 3-Fuel priming pump. 4-Governor. 5-Fuel injection pump housing. 6-Fuel filter. 7-Fuel transfer pump. 8-Tachometer drive.Governor
Removal and Installation
Refer to SERVICE GUIDE for Preliminary Information.
1-Cover. 2-Plate. 3-Cover assembly.
4-Collar. 5-Housing assembly.
6-Spring. 7-Weight assembly.Governor Disassembly and Assembly
1 Guide must be damaged to be removed. When installing a new guide, form the end of the guide against and all the way around the chamfer in the governor housing.2 When assembling weights to carrier, stake four places around each dowel on both ends. Each weight must have .001-.007 in. (0,03-0,18 mm) end play and pivot freely on its dowel.Fuel Transfer Pump
Refer to SERVICE GUIDE for Preliminary Information.8S6747 Sealing Compound 1,3 Apply a thin film of 8S6747 Sealing Compound to mating surfaces when assembling. Do not allow compound to enter pump.2 Use suitable puller and step plate to remove gear. Refer to GENERAL INSTRUCTIONS. Lubricate gear teeth with multipurpose grease before assembling pump to engine.Tachometer Drive
Fuel Pump Housing
Refer to SERVICE GUIDE for Preliminary Information. 8S2315 Wrench8S2244 Extractor.1, 2, 5 Inspect seals.3 Tighten nozzle finger tight on body.4 Use 8S2315 Wrench to remove.6 Use 8S2244 Extractor to remove and install fuel pumps. When installing, sight down the pump and align the notches in the bonnet and barrel with the mark 180° from the pump gear segment center tooth. Position the pump so the notches align with the guide pins in the housing bore. Align the pump gear segment center tooth with the fuel rack center notch. Install the pump. Keep a downward force on the pump and install bushing (4) until flush with the top of the housing. If the bushing can not be assembled this far by hand, remove it. Realign the components and install again.7 When removing retaining ring, do not damage or lose the check valve or spring retained in the bonnet.8, 9 Use extreme care when inserting plunger into barrel. Barrels and plungers are matched and are not interchangeable.10 Fuel rack must be removed before removing lifters and installed after installing lifters.10, 11 Install each spacer and lifter assembly in the same location from which they were removed. Keep them together and identified as to location.12, 13 Remove bearings (12) and (13) with a suitable driver. When installing, position bearing (12) with oil passages aligned vertically (that is, one at the top and one at the bottom). Install bearing (12) .195" .005" deep from the housing face.14, 15, 16 Use commercially available camshaft bearing removal tools. Align oil hole in bearing (14) with the oil passage in the housing.Fuel Ratio Control
Fuel Priming Pump