101501-2010 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1015012010 220008700a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101501-2010 1015012010

HINO 220008700A 220008700a

Cross reference number

ZEXEL 101501-2010 1015012010

HINO 220008700A 220008700a

Zexel num

Bosch num

Firm num

Name

101501-2010
101501-2011

220008700A HINO

INJECTION-PUMP ASSEMBLY
J07C * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131425-0320

Overflow valve opening pressure kPa 108 88 128

Overflow valve opening pressure kgf/cm2 1.1 0.9 1.3

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-2-4-5- 3

Pre-stroke mm 4 3.97 4.03

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cyl.1-2 deg. 72 71.75 72.25

Difference between angles 2
Cal 1-4 deg. 144 143.75 144.25

Difference between angles 3
Cal 1-5 deg. 216 215.75 216.25

Difference between angles 4
Cal 1-3 deg. 288 287.75 288.25

Injection quantity adjustment

Adjusting point -

Rack position 12.4

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 103.5 101.9 105.1

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 Z

Rack position 9.5+-0.5

Pump speed r/min 415 415 415

Each cylinder's injection qty mm3/st. 12 11 13

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.4)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 103.5 102.5 104.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.6

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 105 101 109

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.35

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 105 101 109

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.8

Pump speed r/min 580 580 580

Average injection quantity mm3/st. 89.5 85.5 93.5

Fixing the lever *

Injection quantity adjustment_07

Adjusting point E

Rack position R1-0.95

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 82.5 78.5 86.5

Fixing the lever *

Injection quantity adjustment_08

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 170 170 180

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Load 1/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.3

Load 1/5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1 0.7 1.3

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min 1190++

Advance angle deg. 1 0.7 1.3

Load 2/5

Timer adjustment_05

Pump speed r/min (1300-50 )

Advance angle deg. 1 0.7 1.3

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_06

Pump speed r/min 1450-50

Advance angle deg. 5.5 5.2 5.8

Load 5/5

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
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T1=J93
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=46mm
----------
a=8deg+-5deg b=36deg+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Use the hole at R = aa (2)Rack position = bb (speed lever full, speed = cc). (3)Free (4)Set the stopper screw. (After setting, apply red paint.)
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aa=50mm bb=16.2+-0.2mm cc=0r/min
----------
a=(40deg) b=30deg+-5deg c=10deg+-5deg d=0deg+-5deg

0000001501 LEVER

1. ASR lever adjustment (1)At pump speed N1 adjust bolt (A) so that ASR lever clearance is approx. L at full load.
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N1=300r/min L=2mm
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