101401-2025 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014012025 220004495b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101401-2025 1014012025

HINO 220004495B 220004495b

Cross reference number

ZEXEL 101401-2025 1014012025

HINO 220004495B 220004495b

Zexel num

Bosch num

Firm num

Name

101401-2025

220004495B HINO

INJECTION-PUMP ASSEMBLY
W04C-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 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 1-3-4-2

Pre-stroke mm 3.2 3.17 3.23

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25

Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25

Injection quantity adjustment

Adjusting point -

Rack position 10.7

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 78.5 76.5 80.5

Max. variation between cylinders % 0 -3 3

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 300 300 300

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(10.7)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 78.5 77.5 79.5

Basic *

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 84.5 82.5 86.5

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 82.3 78.3 86.3

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 62.7 58.7 66.7

Fixing the lever *

Boost pressure kPa 24 24

Boost pressure mmHg 180 180

Injection quantity adjustment_07

Adjusting point E

Rack position -

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 50 48 52

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_08

Adjusting point I

Rack position 14.3+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 110 110 120

Fixing the lever *

Rack limit *

Injection quantity adjustment_09

Adjusting point K

Rack position R2(9)

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 39.3 35.3 43.3

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 650 650 650

Rack position R2(9)

Boost pressure kPa 2 2 4.7

Boost pressure mmHg 15 15 35

Boost compensator adjustment_02

Pump speed r/min 650 650 650

Rack position R1-0.5

Boost pressure kPa 10.7 10.7 10.7

Boost pressure mmHg 80 80 80

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 (3)Boost compensator stroke: BCL
----------
T1=B31 BCL=(1.2)+-0.1mm
----------

Speed control lever angle

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

----------
a=34deg+-5deg b=(43deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=13deg+-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)