101401-2091 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014012091 220005510a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101401-2091 1014012091

HINO 220005510A 220005510a

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Buy INJECTION-PUMP ASSEMBLY 101401-2091 zexel genuine, new aftermarket engine parts with delivery

Service parts 101401-2091 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101040-9252

3. GOVERNOR 105921-1990

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0381

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5050

11. Nozzle and Holder 236001880A

12. Open Pre:MPa(Kqf/cm2) 21.6(220)

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-7280

15. NOZZLE SET

Include in #1:

101401-2091 as INJECTION-PUMP ASSEMBLY

108622-3478 as _

Cross reference number

ZEXEL 101401-2091 1014012091

HINO 220005510A 220005510a

Zexel num

Bosch num

Firm num

Name

101401-2091

220005510A 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 10.8

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 84.2 82.2 86.2

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. 8.6 7.1 10.1

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(10.8)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 84.2 83.2 85.2

Basic *

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.5

Pump speed r/min 1600 1600 1600

Average injection quantity mm3/st. 86.2 82.2 90.2

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.25

Pump speed r/min 1300 1300 1300

Average injection quantity mm3/st. 85.2 81.2 89.2

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_06

Adjusting point D

Rack position R1-0.5

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 65.2 61.2 69.2

Fixing the lever *

Boost pressure kPa 25.3 25.3

Boost pressure mmHg 190 190

Injection quantity adjustment_07

Adjusting point E

Rack position -

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 54.6 50.6 58.6

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. 106 106 116

Fixing the lever *

Rack limit *

Injection quantity adjustment_09

Adjusting point K

Rack position R1-1.8

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 41.4 37.4 45.4

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 R1-1.8

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 12 12 12

Boost pressure mmHg 90 90 90

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. 2.5 2.2 2.8

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=C04 BCL=1.3+-0.1mm
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Speed control lever angle

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

----------
a=34deg+-5deg b=42deg+-3deg

Stop lever angle

N:Engine normal (pump normal) S:Engine stop (1)Set the stopper screw. (2)(Apply red paint after setting.)
----------

----------
a=20deg+-5deg b=(28deg)+-5deg

0000001501 ACTUATOR

(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=9.1~9.4mm P1=66.7kPa(500mmHg) N1=300r/min N2=300r/min
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0000001601 TAMPER PROOF

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=(0.4)mm Rb=R1(10.8)mm Rc=R1(10.8)mm
----------
T=4.9~6.9N-m(0.5~0.7Kgf-m)

0000001701 LEVER

(N) Engine normal (pump normal) (S) Engine stop (A) stopper screw (B) Stop direction (perpendicular) Stop lever adjusting procedure (1)After completing adjustment, confirm that the engine's normal lever angle (pump's normal lever) is within the specifications in the figure above. (2)With the speed lever at Full and the pump speed at Na (specified speed), temporarily set the stopper screw (A) at the rack position Ra. (3)Turn the stopper screw (A) Rb in the stop direction (Nb turns) and set it. Measure the rack position. (Rack position = approx. Rc) (4)After setting, confirm non-injection with the speed lever at idle and pump speed at Nc. (5)After adjustment, apply red paint.
----------
Na=- Ra=5.3mm Rb=1.5mm Nb=1.5 Rc=3.3mm Nc=300r/min
----------
ra=37mm a=20deg+-5deg b=(28deg)+-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)

Information:

2. Remove pipe (1) and the gasket between aftercooler cover (2) and the turbocharger. If necessary, remove the O-ring seals from the pipe.3. Remove the bolts and clamps that hold tube assemblies (3) to each end of the aftercooler. Remove tube assemblies (3) from each end of the aftercooler. If necessary, remove the O-ring seals from the tube assemblies. An O-ring seal on each end of the aftercooler core holds the adapters in position.4. Remove adapters (4) and the gaskets from each end of the aftercooler.5. Remove all bolts (5) that hold aftercooler cover (2) in position. Remove the aftercooler cover and gasket from the engine. 6. Remove aftercooler core (6) and the gasket from the engine. If necessary, remove the O-ring seals from the aftercooler core. Two of the bolts that hold the aftercooler housing in position are on the inside of the aftercooler housing.7. Remove the bolts and spacers that hold aftercooler housing (7) to the engine. Make a note of the location of the spacers. Remove the aftercooler housing and gaskets from the engine.Install Aftercooler
Inspect all O-ring seals and gaskets, and make replacements if necessary. 1. Put the gaskets and aftercooler housing (1) in position on the engine. Install the bolts and spacers that hold the aftercooler housing.2. Install the O-ring seals on the aftercooler core, and put a thin layer of clean engine oil on them. Put the gasket and aftercooler core (2) in position on the engine. 3. Put the gasket and aftercooler cover (3) in position. Install the bolts that hold the aftercooler cover. Force may be required to push the adapters around the O-ring seals on the aftercooler core. Make sure the O-ring seals stay in position on the aftercooler core.4. Put a thin layer of clean engine oil in the bores of adapters (4). Install a gasket and adapter on each end of the aftercooler core. 5. Install the O-ring seals on tube assemblies (5), and put a thin layer of clean engine oil on them. Put the tube assemblies in position on each end of the aftercooler, and install the bolts and clamps that hold them.6. Install the O-ring seals on pipe (6), and put a thin layer of clean engine oil on them. Put the pipe and gasket in position between the aftercooler and the turbocharger. Install the bolts that hold it.7. Fill the radiator with coolant to the correct level. See the Operation & Maintenance Manual.