101602-5080 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016025080 220206230a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-5080 1016025080

HINO 220206230A 220206230a

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Cross reference number

ZEXEL 101602-5080 1016025080

HINO 220206230A 220206230a

Zexel num

Bosch num

Firm num

Name

101602-5080
101602-5081

220206230A HINO

INJECTION-PUMP ASSEMBLY
W06E-T * 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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 3.3 3.25 3.35

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 9.9

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 73 71 75

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point C

Rack position 7.5+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position 10.5++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 85 85 95

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Main spring setting
----------
K=16
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Set the pump speed at aa (2)When pump speed set at bb (3)Stopper bolt setting
----------
aa=900r/min bb=750r/min
----------
a=(2deg)+-5deg b=35deg+-3deg c=(18deg)+-5deg d=(4deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position aa or less, pump speed bb
----------
aa=7mm bb=0r/min
----------
a=27deg+-5deg b=53deg+-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:

Image1.4.1
5. Remove two 135-8573 Bolts from the 268-0555 Hood Group, and remove the 244-8226 Support Assembly.
Image1.5.1
6. Rework the 244-8226 Support Assembly. Refer to the attached images.
Image1.6.1
7. Remove four 135-8573 Bolts from the 268-0555 Hood Group. Remove the 262-2340 Sheet Assembly.
Image1.7.1
8. Rework the 262-2340 Sheet Assembly. Refer to the attached images.
Image1.8.1
10. Attach the 324-4078 Support Assembly to the 262-2340 Sheet Assembly. Use two 135-8573 Bolts and tighten the bolts to a torque of 60+/-10 Nm.
Image1.9.1
11. To attach the 262-2340 Sheet Assembly to the 268-0555 Hood Group, use the four 135-8573 Bolts from Step-7. Tighten the bolts to a torque of 100+/-20 Nm.
12. To attach the 244-8226 Support Assembly to the 268-0555 Hood Group, use the two 135-8573 Bolts from Step-5. Tighten the bolts to a torque of 100+/-20 Nm.
13. To attach the 196-8236 Filter Assembly to the 244-8226 Support Assembly, use the two 8T-4182 Bolts and two 8T-4121 Washers. Tighten the bolts to a torque of 32+/-3 Nm.
Image1.12.1
14. Remove the present fuel hose which connected between the outlet of the fuel priming pump and the inlet of present filter assembly.
Image1.13.1
15. Install the 099-4437 Gasket to both connectors on the 305-4888 Hose. Connect the 305-4888 Hose to the inlet of the new filter assembly using the 094-9726 Bolt and two 095-2040 Washers. Tighten the bolt to a torque of 34+/-4 Nm. Connect the other end of the 305-4888 Hose to the outlet of the fuel priming pump using the bolt and the washer of the priming pump. Tighten the bolt to a torque of 34+/-4 Nm.
16. Install the 7I-7439 Guard( Length is 700mm) to the 305-4888 Hose.
17. Install the 099-4437 Gasket to both connectors on the 305-4887 Hose. Connect the 305-4887 Hose to the outlet of the new filter assembly and inlet of the present filter assembly. Use the 094-9726 Bolt and two 095-2040 Washers in order to connect the hose to the filter assemblies. Tighten the bolts to a torque of 34+/-4 Nm.
18. Install the 7I-7439 Guard (Length is 760mm) to the 305-4887 Hose.
19. Tighten the 094-9725 Plug with the 095-2040 Washer on top of filter base of current fuel filter and additional fuel filter. Tighten the plug to a torque of 8.8+/-1 Nm.
Image1.18.1
20. Use the 294-1833 Clamp, 7X-2533 Bolt, and the 9X-8256 Washer in order to clamp the fuel hose. Tighten the bolt to a torque of 10+/-1 Nm.
Image1.19.1
21. Use two 294-1831 Clamps, 7X-2535 Bolt, two 9X-8256 Washers, and the 5C-2890 Nut in order to clamp the fuel hose. Tighten the bolt to a torque of 10+/-1 Nm.
22. Re-install the two air intake hoses, using the two 8T-4985 Clamps from Step-4. Tighten the clamps to a torque of 4.5+/-0.5 Nm.
Image1.21.1
23. Re-attach the 244-8212 Cover Assembly to the 268-0555 Hood Group. Use the two 135-8573 Bolts, two 135-8575 Bolts, and two 170-3016 Spacers from Step-2. Tighten the bolts to a torque of 100+/-20 Nm.