101601-2831 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016012831 220801175b


101601-2831 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101601-2831 1016012831
HINO 220801175B 220801175b

Cross reference number

ZEXEL 101601-2831 1016012831
HINO 220801175B 220801175b


Zexel num
Bosch num
Firm num
Name
101601-2831 
 
220801175B  HINO
INJECTION-PUMP ASSEMBLY
H07C * 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   1-4-2-6- 3-5
Pre-stroke mm   3.1 3.07 3.13
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   A
Rack position   6.9
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   65 64 66
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_02
Adjusting point   B
Rack position   5+-0.5
Pump speed r/min   375 375 375
Average injection quantity mm3/st.   8 7 9
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   C
Rack position   10.8+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   125 125 135
Fixing the lever   *
Rack limit   *
Injection quantity adjustment_04
Adjusting point   E
Rack position   7.2
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   56 55 57
Fixing the lever   *

Test data Ex:

Governor adjustment

Test data 101601-2831
N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)RACK LIMIT
----------
DL=6-0.2mm
----------

Timer adjustment

Test data 101601-2831
(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N2=800r/min C2=(5.7)deg t1=2--sec. t2=2--sec.
----------
N1=1200++r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=5.7+-0.3deg R01=0/4load R02=4/4load

Speed control lever angle

Test data 101601-2831
F:Full speed
----------

----------
a=21deg+-5deg

0000000901

Test data 101601-2831
F:Full load I:Idle (1)Use the hole at R = aa (2)Stopper bolt setting
----------
aa=60mm
----------
a=25.5deg+-3deg b=7deg+-5deg

Stop lever angle

Test data 101601-2831
N:Pump normal S:Stop the pump.
----------

----------
a=35deg+-5deg b=50deg+-5deg

0000001501 RACK SENSOR

Test data 101601-2831
V1:Supply voltage V2f:Full side output voltage V2i:Idle side output voltage (A) Black (B) Yellow (C) Red (D) Trimmer (E): Shaft (F) Nut (G) Load lever 1. Load sensor adjustment (1)Connect as shown in the above diagram and apply supply voltage V1. (2)Hold the load lever (G) against the full side. (3)Turn the shaft so that the voltage between (A) and (B) is V2. (4)Hold the load lever (G) against the idle side. (5)Adjust (D) so that the voltage between (A) and (B) is V2i. (6)Repeat the above adjustments. (7)Tighten the nut (F) at the point satisfying the standards. (8)Hold the load lever against the full side stopper and the idle side stopper. (9)At this time, confirm that the full side output voltage is V2f and the idle side output voltage is V2i.
----------
V1=5+-0.02V V2f=0.15+0.03V V2i=2.35-0.03V
----------

Timing setting

Test data 101601-2831
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)




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