101601-5381 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015381 220005970a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5381 1016015381

HINO 220005970A 220005970a

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Buy INJECTION-PUMP ASSEMBLY 101601-5381 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-5381 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-9891

3. GOVERNOR 105921-2830

4. SUPPLY PUMP 105220-5140

5. AUTOM. ADVANCE MECHANIS 105676-0221

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:

101601-5381 as INJECTION-PUMP ASSEMBLY

106682-9593 as _

Cross reference number

ZEXEL 101601-5381 1016015381

HINO 220005970A 220005970a

Zexel num

Bosch num

Firm num

Name

101601-5381

220005970A 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 8.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 46.6 44.6 48.6

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. 46.6 45.6 47.6

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. 45.2 43.2 47.2

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. 52 50 54

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 36 40

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1+0.35

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 28 24 32

Fixing the lever *

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. 3.5 3.2 3.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=A76 RAL=(R1+0.2)+0.2mm
----------

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:

37. Remove races (70) and (72) and bearing (71) from the camshaft in the fuel injection pump housing. Assemble Governor
1. Put the fuel injection pump housing in position on tool (A). Install race (3), bearing (2) and race (1) on the end of the camshaft in the fuel injection pump housing. 2. Put flyweights (5) in position on carrier assembly (4), and install dowels (6) to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.230 mm (.0004 to .0090 in) end play. 3. Install governor shaft (7) on carrier assembly (4). 4. Install dowel (8) in governor shaft (7), and slide carrier assembly (4) down on the governor shaft until dowel (8) fits into the slot in the carrier assembly.5. Install carrier assembly (4) on the end of the camshaft. 6. Install race (12), bearing (11), race (10) and ring (9) on riser (13). 7. Install riser (13) and spring (14), if equipped, on the governor shaft. 8. Install spool (18) and ring (19) on seat (17), and use tool (B) to install ring (20) to hold them in position.9. Install seat (17) on spring (16) and spring (16) on shield (15). 10. Install dashpot assembly (21) on the governor shaft. 11. Install ring (22) in the groove on the governor shaft. Install sleeve (23), spring (25), the sleeve and bearing (24) on the governor shaft. 12. Use tool (C) to hold spring (25) under compression, and install the ring in the groove on the governor shaft. 13. Install O-ring seal (26) on sleeve (27). Install piston (29) and sleeve (27) in the governor servo as shown.14. Install valve (28) in the governor servo as shown. 15. Install lockring (33) in the groove near the center of valve (28). Put sleeve (34), spring (broken link spring) (35) and seat (36) in position on valve (28), and install lockring (37) to hold them in place. 16. Put governor servo (30) in position on the fuel injection pump housing with piston (29) engaged over the rack. Make sure the lever is engaged in the (slot) groove of riser (13). 17. If dowel (43) was removed, install it in block (44) 31 0.5 mm (1.22 .02 in) above the outside surface of the block.18. Install bolt (45) in block (44) and spring (38) on bolt (45).19. Install stop screw (40) and the locknut on collar (42). Install power setting screw (41) and the locknut on the collar.20. Install collar (42) on bolt (45). Make an alignment of the hole in the collar with the notch in bolt (45), and install bolt (39). 21. If the dowels that align block (44) with the front governor housing were removed, install them 4.0 0.5 mm (.16 .02 in) above the outside surface of the front governor housing.22. Put block (44) in position on the front governor housing with the holes in the block in alignment with dowels in the front governor