101401-2131 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014012131 220005781a


101401-2131 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101401-2131 1014012131
HINO 220005781A 220005781a

Cross reference number

ZEXEL 101401-2131 1014012131
HINO 220005781A 220005781a


Zexel num
Bosch num
Firm num
Name
101401-2131 
101401-2134 
 
220005781A  HINO
INJECTION-PUMP ASSEMBLY
W04CTD *

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   4.4 4.37 4.43
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   12.1
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   98.5 96.5 100.5
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   9.2+-0.5
Pump speed r/min   325 325 325
Average injection quantity mm3/st.   20.8 19.3 22.3
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(12.1)
Pump speed r/min   1100 1100 1100
Average injection quantity mm3/st.   98.5 97.5 99.5
Basic   *
Fixing the lever   *
Boost pressure kPa   22.7 22.7
Boost pressure mmHg   170 170
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   1600 1600 1600
Average injection quantity mm3/st.   93.7 89.7 97.7
Fixing the lever   *
Boost pressure kPa   22.7 22.7
Boost pressure mmHg   170 170
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-1.25
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   67.3 63.3 71.3
Fixing the lever   *
Boost pressure kPa   22.7 22.7
Boost pressure mmHg   170 170
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1-1
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   78.1 74.1 82.1
Fixing the lever   *
Boost pressure kPa   22.7 22.7
Boost pressure mmHg   170 170
Injection quantity adjustment_07
Adjusting point   E
Rack position   -
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   52 48 56
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_08
Adjusting point   F
Rack position   R2-0.95
Pump speed r/min   650 650 650
Average injection quantity mm3/st.   43.4 39.4 47.4
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_09
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   115 115 130
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   650 650 650
Rack position   R2-0.95
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   R2(R1-1. 25)
Boost pressure kPa   9.3 9.3 9.3
Boost pressure mmHg   70 70 70
Timer adjustment
Pump speed r/min   1350--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1300
Advance angle deg.   0.3
Timer adjustment_03
Pump speed r/min   1600
Advance angle deg.   3.5 3.2 3.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101401-2131
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=D13 BCL=0.95+-0.1mm
----------

Speed control lever angle

Test data 101401-2131
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=50mm
----------
a=34deg+-5deg b=40deg+-3deg

Stop lever angle

Test data 101401-2131
N:Engine normal (pump normal) S:Engine stop (1)Set the stopper screw. (After setting, apply red paint.)
----------

----------
a=20deg+-5deg b=26deg+-5deg

0000001501 TAMPER PROOF

Test data 101401-2131
1. Method for setting tamperproof proofing (1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to Ra. (2)At pump speed N1, push in the screw (A) until the rack position is Rb. (3)Temporarily caulk using the tip of a screwdriver (4)Confirm that the rack at that time is at Rc. (5)Lock using setscrew (B). (Tightening torque = T) (6)Next, coat (C) with adhesive and then pressfit. (7)Then, readjust the full rack position using the load lever.
----------
N1=1600r/min Ra=1mm Rb=R1(12.1)+0.2mm Rc=R1(12.1)+0.2mm
----------
T=4.9~6.9N-m(0.5~0.7Kgf-m)

0000001601 ACTUATOR

Test data 101401-2131
(a) Screw (B) Nut (c) set bolt (d) control lever 1. Actuator adjustment procedure (1)Position the control lever (d) in the idling position. (2)Set the clearance between the control lever (d) and the set bolt (c) to approx. L1. (3)Loosen the nut (b) and fully tighten the screw (a). (4)Set the pump speed at N1and measure the rack position when negative pressure P1 is applied to the actuator. (5)Loosen screw (a) and fix the nut (b) when the pump speed is N2 and the rack position is R1. (6)Confirm that control lever (d) returns to the idling position at actuator negative pressure 0. (7)Repeat procedures (4) to (6) several times and confirm that the control lever (d) moves smoothly.
----------
L1=2mm R1=10.1~10.4mm P1=66.7kPa(500mmHg) N1=325r/min N2=325r/min
----------

Timing setting

Test data 101401-2131
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)




Have questions with 101401-2131?





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