101601-5711 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015711 220006801a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-5711 1016015711

HINO 220006801A 220006801a

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Service parts 101601-5711 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3831

3. GOVERNOR 105921-4281

4. SUPPLY PUMP 105210-4990

5. AUTOM. ADVANCE MECHANIS 105672-0120

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6280

11. Nozzle and Holder 23600-2133

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105030-4300

14. NOZZLE

105015-8590

15. NOZZLE SET

Include in #1:

101601-5711 as INJECTION-PUMP ASSEMBLY

104303-3480 as _

Cross reference number

ZEXEL 101601-5711 1016015711

HINO 220006801A 220006801a

Zexel num

Bosch num

Firm num

Name

101601-5711
101601-5712

220006801A HINO

INJECTION-PUMP ASSEMBLY
H07D-A A * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8210

Nozzle 105780-0070

Bosch type code DN12SD12T-1

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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 3.8 3.77 3.83

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 11.5

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77.6 76 79.2

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 9+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 16.9 15.9 17.9

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.5)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 77.6 76.6 78.6

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.5

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 88.9 84.9 92.9

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.3

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 64.2 60.2 68.2

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.5

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 87.4 83.4 91.4

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 150

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 925--

Advance angle deg. 0 0 0

Load 1/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 875

Advance angle deg. 0.3

Load 1/4

Timer adjustment_03

Pump speed r/min (920--)

Advance angle deg. 1 0.7 1.3

Load 4/4

Timer adjustment_04

Pump speed r/min 1175+50

Advance angle deg. 1 0.7 1.3

Load 3/4

Timer adjustment_05

Pump speed r/min 1400+50

Advance angle deg. 5.5 5.2 5.8

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=F03
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=57mm
----------
a=(40deg)+-3deg b=44deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(50deg)

Information:

Cleaning Primary Filter
Use all cleaning solutions with care.
1. Loosen the bolt (1) on the filter cover and lower the filter case (3).2. Remove the element (2). Wash the cover and element in clean, nonflammable solvent.3. Reinstall the element into the case.4. Install the element and case onto the cover.5. Tighten the bolt.Changing Secondary Filter
1. Unscrew filter element. Throw away the used element. 2. Make certain all of the used element seal is cleaned from the filter base. 3. Coat the seal of the new element with clean diesel fuel.
Do not fill fuel filters with fuel before installing them. Contaminated fuel will cause accelerated wear to fuel system parts.
4. Install the filter by hand. When the seal contacts the base, tighten 3/4 turn more. There are rotation marks 90° apart on the filter. Use these as a guide for proper tightening.5. Start the engine and check for leaks. If the engine will not start, prime the fuel system.