Information injection-pump assembly
ZEXEL
101401-2131
1014012131
HINO
220005781A
220005781a
Rating:
Cross reference number
ZEXEL
101401-2131
1014012131
HINO
220005781A
220005781a
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
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
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
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=D13 BCL=0.95+-0.1mm
----------
----------
T1=D13 BCL=0.95+-0.1mm
----------
Speed control lever angle
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
----------
aa=50mm
----------
a=34deg+-5deg b=40deg+-3deg
Stop lever angle
N:Engine normal (pump normal)
S:Engine stop
(1)Set the stopper screw. (After setting, apply red paint.)
----------
----------
a=20deg+-5deg b=26deg+-5deg
----------
----------
a=20deg+-5deg b=26deg+-5deg
0000001501 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=1mm Rb=R1(12.1)+0.2mm Rc=R1(12.1)+0.2mm
----------
T=4.9~6.9N-m(0.5~0.7Kgf-m)
----------
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
(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
----------
----------
L1=2mm R1=10.1~10.4mm P1=66.7kPa(500mmHg) N1=325r/min N2=325r/min
----------
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)
----------
----------
a=(70deg)
Information:
Typical Example1. Turn the crankshaft until the "C" mark on the crankshaft gear is in alignment with the "C" mark on the camshaft gear. To keep the engine timing correct during removal and installation of the camshaft, put a mark on the teeth of the fuel injection pump drive gear and idler gear at location (A). Put a mark on the teeth of the idler gear and camshaft gear at location (B). When installing the camshaft, the engine timing will be correct when the marks at locations (A) and (B) are in alignment and the "C" marks on the crankshaft and camshaft gears are in alignment.2. Remove the bolts, lock and washer (1) that hold the camshaft in position.3. Remove the camshaft and gear (2). Do not cause damage to the lobes or bearings when the camshaft is removed.4. If necessary, remove the bolts and gear from the camshaft. The following steps are for the installation of the camshaft.5. Put the camshaft drive gear in position on the end of the camshaft, and install the bolts that hold it. Tighten the bolts to a torque of 55 7 N m (41 5 lb ft).
Do not cause damage to the lobes or bearings when the camshaft is installed.
6. Put 2P2506 Thread Lubricant on the camshaft lobes only, and clean engine oil on the bearing journals. Install camshaft (3) in the cylinder block, and make an alignment of the "C" marks and the marks put on the gears during removal.7. Install washer (1), the lock and bolts to hold the camshaft in position.End By:a. install valve liftersb. install timing gear cover