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

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5202 1016015202

HINO 220005240A 220005240a

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Buy INJECTION-PUMP ASSEMBLY 101601-5202 zexel genuine, new aftermarket engine parts with delivery

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

106682-4731 as _

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

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

Speed control lever angle

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

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

Stop lever angle

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

(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

(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:

Start By:
Keep all parts clean from contaminants. Contaminants put into the system may cause rapid wear and shortened component life.
a. remove crankshaft rear seal and wear sleeve1. Loosen the bolts that hold the oil pan and oil plan plate to the cylinder block. Remove the bolts that hold the oil pan plate to the flywheel housing.2. Install spacers between the oil pan plate and the cylinder block to hold the oil pan plate away from the flywheel housing. 3. Remove turbocharger oil drain tube (1).4. Remove the bolt to clip (3).5. Install tool (A) and fasten a hoist as shown. Remove bolts (4) and remove flywheel housing (2). The weight of the flywheel housing is 39 kg (85 lb.). The following steps are for the installation of the flywheel housing.6. Clean the old gasket from the surfaces of the cylinder block and flywheel housing that make contact with each other. Install a new gasket on the cylinder block.7. Install two 1/2" - 13 NC guide bolts in the cylinder block. Install tool (A) on the flywheel housing. Fasten a hoist and put the flywheel housing in position on the guide bolts. Install all but two bolts in the flywheel housing. Remove tool (A) and the guide bolts. Install the other two bolts. Tighten the flywheel housing bolts in the sequence as shown. 8. Cut the bottom of the gasket even with the flywheel housing and cylinder block. Put 5H2471 Gasket Cement on the bottom of the gasket where the gasket makes contact with the gasket for the oil pan plate. Remove shims from each side of the engine. Tighten all of the oil pan bolts. Install the bolts that hold the oil pan plate to the flywheel housing.9. Install the bolt to clip (3). Install turbocharger oil drain tube (1).End By:a. install crankshaft rear seal and wear sleeve