101601-5370 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015370 220005940a


101601-5370 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101601-5370 1016015370
HINO 220005940A 220005940a

Cross reference number

ZEXEL 101601-5370 1016015370
HINO 220005940A 220005940a


Zexel num
Bosch num
Firm num
Name
101601-5370 
101601-5372 
 
220005940A  HINO
INJECTION-PUMP ASSEMBLY
W06E *

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   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   -
Rack position   9.6
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   57.9 55.9 59.9
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   H
Rack position   7.8+-0.5
Pump speed r/min   250 250 250
Average injection quantity mm3/st.   5.3 3.8 6.8
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(9.6)
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   57.9 56.9 58.9
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1(9.6)
Pump speed r/min   1500 1500 1500
Average injection quantity mm3/st.   63.9 59.9 67.9
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.25
Pump speed r/min   600 600 600
Average injection quantity mm3/st.   40.3 36.3 44.3
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1(9.6)
Pump speed r/min   1200 1200 1200
Average injection quantity mm3/st.   63.7 59.7 67.7
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   E
Rack position   R1+0.45
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   39.9 35.9 43.9
Fixing the lever   *
Injection quantity adjustment_08
Adjusting point   I
Rack position   14.5+-0. 5
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   108 108 118
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   1200+50
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   1500
Advance angle deg.   4.5 4.2 4.8
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-5370
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=C02
----------

Speed control lever angle

Test data 101601-5370
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=37deg+-5deg b=(40deg)+-3deg

Stop lever angle

Test data 101601-5370
N:Pump normal S:Stop the pump.
----------

----------
a=40deg+-5deg b=40deg+-5deg

0000001501 AIR CYLINDER

Test data 101601-5370
(A): Speed lever (B): Set bolt (C): air cylinder (D): nut (E): fix 1. Air cylinder adjustment procedure (1)With the speed lever in the idling position, temporarily set the clearance between speed lever (A) and set bolt (B) at approximately L1. (2)Set the speed to N1 and supply positive pressure P1 to the air cylinder (C). (3)Gradually push set bolt (B) out (approximately L2) and tighten nut (D) where the speed is N2 and the rack position is Ra. (4)Apply positive pressure P1 several times. (5)Confirm that the lever returns to the idle position at positive pressure P2. (6)Also, confirm that the rack position is Rb at air pressure P1.
----------
L1=5mm L2=1.4mm Ra=7.3+-0.1mm Rb=7.3+-0.1mm N1=475r/min N2=475r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
----------

Timing setting

Test data 101601-5370
(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




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