101601-5260 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015260 220005320a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5260 1016015260

HINO 220005320A 220005320a

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Cross reference number

ZEXEL 101601-5260 1016015260

HINO 220005320A 220005320a

Zexel num

Bosch num

Firm num

Name

101601-5260
101601-5262

220005320A HINO

INJECTION-PUMP ASSEMBLY
W06E *

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 10.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 57.9 55.9 59.9

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 8.3+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 5.3 3.8 6.8

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(10.1)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 57.9 56.9 58.9

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(10.1)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 63.9 59.9 67.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 40.3 36.3 44.3

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1(10.1)

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 63.7 59.7 67.7

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.45

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 39.9 35.9 43.9

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position 15+-0.5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 108 108 118

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1200+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

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=C11
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=50mm
----------
a=46deg+-5deg b=(47deg)+-3deg

Stop lever angle

N:Engine normal (pump normal) S:Engine stop (1)Set the stopper screw. (After setting, apply red paint.) (2)-
----------

----------
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:

6N1301 Flywheel AssemblyMake reference to Flywheel Runout for the correct method of flywheel inspection.(1) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N m (200 20 lb ft)(2) Maximum permissible temperature of the gear for installation on the flywheel (do not use a torch) ... 315°C (600°F)9N0018 Flywheel Group
9N2648 Flywheel AssemblyMake reference to Flywheel Runout for the correct method of flywheel inspection.(1) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N m (200 20 lb ft)(2) Maximum permissible temperature of the gear for installation on the flywheel (do not use a torch) ... 315°C (600°F)9N0676 Flywheel Group
9N2649 Flywheel AssemblyMake reference to Flywheel Runout for the correct method of flywheel inspection.(1) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N m (200 20 lb ft)(2) Maximum permissible temperature of the gear for installation on the flywheel (do not use a torch) ... 315°C (600°F)9N0678 Flywheel Group
4W6730 FlywheelMake reference to Flywheel Runout for correct method of flywheel inspection.(1) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N m (200 20 lb ft)4P3740 Flywheel Group
4P4797 Flywheel AssemblyMake reference to Flywheel Runout for the correct method of flywheel inspection.(1) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N m (200 20 lb ft)(2) Maximum permissible temperature of the gear for installation on the flywheel (do not use a torch) ... 315°C (600°F)4P4795 Flywheel Group
4P4795 FlywheelMake reference to Flywheel Runout for correct method of flywheel inspection.(1) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N m (200 20 lb ft)4P8170 Flywheel Group
4P8169 Flywheel AssemblyMake reference to Flywheel Runout for the correct method of flywheel inspection.(1) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N m (200 20 lb ft)(2) Maximum permissible temperature of the gear for installation on the flywheel (do not use a torch) ... 315°C (600°F)4W7370 Flywheel Group
4W7186 Flywheel AssemblyMake reference to Flywheel Runout for the correct method of flywheel inspection.(1) Maximum permissible temperature of the gear for installation on the flywheel (do not use a torch) ... 315°C (600°F)(2) Put 2P2506 Thread Lubricant on all bolt threads that hold flywheel to crankshaft and tighten to a torque of ... 270 25 N (200 20 lb ft)(3) Bore in bushing ... 52.007 0.013 mm (2.0475 .0005 in)(4) Diameter of bushing ... 72.022 0.015 mm (2.8355 .0006 in) Bore in flywheel ... 71.971