Information injection-pump assembly
ZEXEL
101401-2211
1014012211
HINO
220006301A
220006301a
Rating:
Cross reference number
ZEXEL
101401-2211
1014012211
HINO
220006301A
220006301a
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
3.2
3.17
3.23
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
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
74.8
72.8
76.8
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
9.5+-0.5
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
8.5
7
10
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)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
74.8
73.8
75.8
Basic
*
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1-0.6
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
78.6
74.6
82.6
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.4
Pump speed
r/min
650
650
650
Average injection quantity
mm3/st.
56.4
52.4
60.4
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_06
Adjusting point
D
Rack position
R2(12)
Pump speed
r/min
300
300
300
Average injection quantity
mm3/st.
52.2
50.2
54.2
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_07
Adjusting point
E
Rack position
R1-0.4
Pump speed
r/min
1300
1300
1300
Average injection quantity
mm3/st.
77.2
73.2
81.2
Fixing the lever
*
Boost pressure
kPa
26
26
Boost pressure
mmHg
195
195
Injection quantity adjustment_08
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
107
107
117
Fixing the lever
*
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
300
300
300
Rack position
R2(12)
Boost pressure
kPa
2
2
4.7
Boost pressure
mmHg
15
15
35
Boost compensator adjustment_02
Pump speed
r/min
300
300
300
Rack position
R1+1.3
Boost pressure
kPa
12.7
12.7
12.7
Boost pressure
mmHg
95
95
95
Timer adjustment
Pump speed
r/min
1010--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
960
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
1060
Advance angle
deg.
1.5
1.2
1.8
Load
4/4
Timer adjustment_04
Pump speed
r/min
1280
Advance angle
deg.
1.8
Load
3/4
Timer adjustment_05
Pump speed
r/min
1600
Advance angle
deg.
4.5
4.2
4.8
Load
4/4
Remarks
Finish
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
(4)Boost compensator stroke: BCL
----------
T1=D94 BCL=(1.3)+-0.1mm
----------
----------
T1=D94 BCL=(1.3)+-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=21.5deg+-5deg b=43deg+-3deg
----------
aa=50mm
----------
a=21.5deg+-5deg b=43deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
----------
----------
a=13deg+-5deg b=40deg+-5deg
----------
----------
a=13deg+-5deg b=40deg+-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=10.6~10.9mm P1=66.7kPa(500mmHg) N1=300r/min N2=300r/min
----------
----------
L1=2mm R1=10.6~10.9mm P1=66.7kPa(500mmHg) N1=300r/min N2=300r/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:
Assemble Governor
*Pump and Governor Reconditioning Tool Group1. Put the fuel injection pump housing in position on Tool (A). Install race (3), bearing (2) and race (1) on the end of the camshaft in the fuel injection pump housing. 2. Put flyweights (5) in position on carrier assembly (4), and install dowels (6) to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.230 mm (.0004 to .0090 in) end play. 3. Install governor shaft (7) on carrier assembly (4). 4. Install dowel (8) in governor shaft (7), and slide carrier assembly (4) down on the governor shaft until dowel (8) fits into the slot in the carrier assembly.5. Install carrier assembly (4) on the end of the camshaft. 6. Install race (12), bearing (11), race (10) and ring (9) on riser (13). 7. Install riser (13) and spring (14), if equipped, on the governor shaft. 8. Install spool (18) and ring (19) on seat (17), and use Tool (B) to install ring (20) to hold them in position.9. Install seat (17) on spring (16) and spring (16) on shield (15). 10. Install dashpot assembly (21) on the governor shaft. 11. Install ring (22) in the groove on the governor shaft. Install sleeve (23), spring (25), the sleeve and bearing (24) on the governor shaft. 12. Use Tool (C) to hold spring (25) under compression, and install the ring in the groove on the governor shaft. 13. Install O-ring seal (26) on sleeve (27). Install piston (29) and sleeve (27) in the governor servo as shown.14. Install valve (28) in the governor servo as shown. 15. Install lockring (33) in the groove near the center of valve (28). Put sleeve (34), spring broken link spring (35) and seat (36) in position on valve (28), and install lockring (37) to hold them in place. 16. Put governor servo (30) in position on the fuel injection pump housing with piston (29) engaged over the rack. Make sure the lever is engaged in the slot groove of riser (13). 17. If dowel (43) was removed, install it in block (44) 31 0.5 mm (1.22 .02 in) above the outside surface of the block.18. Install bolt (45) in block (44) and spring (38) on bolt (45).19. Install stop screw (40) and the locknut on collar (42). Install power setting screw (41) and the locknut on the collar.20. Install collar (42) on bolt (45). Make an alignment of the hole in the collar with the notch in bolt (45), and install bolt (39). 21. If the dowels that align block (44) with the front governor housing were removed, install them 4.0 0.5 mm (.16 .02 in) above the outside surface of the front governor housing.22. Put block (44) in position on the front governor housing with the holes in the block in alignment with dowels in the front governor housing. 23. Install dowels (46) in the front governor housing 6.0 0.5
*Pump and Governor Reconditioning Tool Group1. Put the fuel injection pump housing in position on Tool (A). Install race (3), bearing (2) and race (1) on the end of the camshaft in the fuel injection pump housing. 2. Put flyweights (5) in position on carrier assembly (4), and install dowels (6) to hold the flyweights in place. The flyweights must move freely on the dowels and have 0.010 to 0.230 mm (.0004 to .0090 in) end play. 3. Install governor shaft (7) on carrier assembly (4). 4. Install dowel (8) in governor shaft (7), and slide carrier assembly (4) down on the governor shaft until dowel (8) fits into the slot in the carrier assembly.5. Install carrier assembly (4) on the end of the camshaft. 6. Install race (12), bearing (11), race (10) and ring (9) on riser (13). 7. Install riser (13) and spring (14), if equipped, on the governor shaft. 8. Install spool (18) and ring (19) on seat (17), and use Tool (B) to install ring (20) to hold them in position.9. Install seat (17) on spring (16) and spring (16) on shield (15). 10. Install dashpot assembly (21) on the governor shaft. 11. Install ring (22) in the groove on the governor shaft. Install sleeve (23), spring (25), the sleeve and bearing (24) on the governor shaft. 12. Use Tool (C) to hold spring (25) under compression, and install the ring in the groove on the governor shaft. 13. Install O-ring seal (26) on sleeve (27). Install piston (29) and sleeve (27) in the governor servo as shown.14. Install valve (28) in the governor servo as shown. 15. Install lockring (33) in the groove near the center of valve (28). Put sleeve (34), spring broken link spring (35) and seat (36) in position on valve (28), and install lockring (37) to hold them in place. 16. Put governor servo (30) in position on the fuel injection pump housing with piston (29) engaged over the rack. Make sure the lever is engaged in the slot groove of riser (13). 17. If dowel (43) was removed, install it in block (44) 31 0.5 mm (1.22 .02 in) above the outside surface of the block.18. Install bolt (45) in block (44) and spring (38) on bolt (45).19. Install stop screw (40) and the locknut on collar (42). Install power setting screw (41) and the locknut on the collar.20. Install collar (42) on bolt (45). Make an alignment of the hole in the collar with the notch in bolt (45), and install bolt (39). 21. If the dowels that align block (44) with the front governor housing were removed, install them 4.0 0.5 mm (.16 .02 in) above the outside surface of the front governor housing.22. Put block (44) in position on the front governor housing with the holes in the block in alignment with dowels in the front governor housing. 23. Install dowels (46) in the front governor housing 6.0 0.5