101601-5032 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015032 220004711a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5032 1016015032

HINO 220004711A 220004711a

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Buy INJECTION-PUMP ASSEMBLY 101601-5032 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-5032 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9891

3. GOVERNOR 105921-0460

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0241

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:

101601-5032 as INJECTION-PUMP ASSEMBLY

106682-9190 as _

Cross reference number

ZEXEL 101601-5032 1016015032

HINO 220004711A 220004711a

Zexel num

Bosch num

Firm num

Name

101601-5032

220004711A 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 8.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 49.2 47.2 51.2

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(8.8)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 49.2 48.2 50.2

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. 45 43 47

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. 55.7 53.7 57.7

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. 38.7 36.7 40.7

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=90
----------

Speed control lever angle

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

----------
a=33deg+-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:

1. Disconnect oil supply line (1) and oil drain tube (2). Remove the four mounting nuts and remove the turbocharger. Remove the gasket. The following steps are for the installation of the turbocharger.2. Apply 5P3931 Anti-Seize to turbocharger mounting studs. Position turbocharger gasket and turbocharger, then Install the four mounting nuts. Tighten the four mounting nuts to a torque of 54 5 N m (40 4 lb.ft.).3. Position gaskets and install drain tube (2) and supply line (1).Disassemble And Assemble Turbocharger
Start By:a. remove turbocharger 1. Remove bolts (1) and (2). Remove the compressor and turbine housings.2. Remove nut (3) and compressor wheel (4). Slide out turbine wheel (5) and shaft.3. Remove adapter plate snap ring (6).4. Use two screwdrivers and remove adapter plate (7).5. Remove bushings (8), spacers (9), and seals (10).6. Remove snap ring (11) and bushing (12).7. Remove snap ring (13) and bushing (14). The following steps are for the assembly of the turbocharger.8. Install bushing (12) and snap ring (11). Repeat for bushing (14) and snap ring (13).9. With th seals and shield (15) in place, install shaft and turbine wheel assembly (5).10. Install the spacers, bushings, plate, seals and adapter plate. Install the snap ring (not illustrated).
Do not allow any of the 7M7456 Locktite to get on the shaft. Damage to the turbocharger may occur.
11. Install compressor wheel (4) on the shaft. Put one drop of 7M7456 Locktite on the threads and install nut (3). Tighten nut (3) to a torque of 15.6 .7 N m (138 6 lb.in.).12. Position the turbine and compressor housings. Put 5P3931 Anti-Seize Compound on the bolts and install. Tighten bolts (1) for the compressor cover to a torque of 7.3 .6 N m (65 5 lb.in.). Tighten bolts (2), for the turbine housing to a torque of 15.8 .6 N m (140 5 lb.in.).End by:a. Install turbocharger