101402-2240 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014022240 220204130a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101402-2240 1014022240

HINO 220204130A 220204130a

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Cross reference number

ZEXEL 101402-2240 1014022240

HINO 220204130A 220204130a

Zexel num

Bosch num

Firm num

Name

101402-2240
101402-2241

220204130A HINO

INJECTION-PUMP ASSEMBLY
W04C-T * K

101402-2240
101402-2241

S220204130A HINO

INJECTION-PUMP ASSEMBLY
W04C-T A * 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 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 1-3-4-2

Pre-stroke mm 4.4 4.35 4.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 9.7

Pump speed r/min 1175 1175 1175

Average injection quantity mm3/st. 65 63 67

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.4

Pump speed r/min 425 425 425

Average injection quantity mm3/st. 9 7.5 10.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 100 100 110

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
K=11
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=(23deg)+-5deg b=(38deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.2mm
----------
a=21deg+-5deg b=(55deg)

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:

Illustration 1 g06140436
(1) 277-7637 Bracket
(2) 8T-3490 Weld NutWeld the 8T-3490 Weld Nut (2) on the 277-7637 Bracket (1) as shown in Illustration 1.
Illustration 2 g06140437
Weld location
Illustration 3 g06140439
View of area A
(1) Welded bracket
Illustration 4 g06140464
(B) 10 mm (0.4 inch)
(C) 36 mm (1.4 inch)
(E) 27 mm (1.1 inch)
(W1) 3 mm (0.1 inch) Fillet weldWeld the 277-7637 Bracket (1) on the frame as shown in Illustration 4.CEM Hose Removal and Install Procedure
Illustration 5 g06140472
(3) 418-2057 Hose
(4) 418-2055 HoseRemove the 418-2057 Hose (3) and the 418-2055 Hose (4).
Illustration 6 g06140489
(5) 428-8808 Hose Clamp
(6) 468-4707 Hose
(7) 326-4516 Cable Tie
(8) 468-4709 Hose
(9) 449-2092 Hose
(10) 428-8808 Hose Clamp
Assemble the 468-4707 Hose (6), the 468-4709 Hose (8), and the 449-2092 Hose (9) as shown in Illustration 6.
Secure the 468-4707 Hose (6) with a 326-4516 Cable Tie (7)
Tighten the two 428-8808 Hose Clamps (5) to 6.5 to 6.8 N m (58 to 60 lb in).
Tighten the four 428-8808 Hose Clamps (10) to 6.5 to 6.8 N m (58 to 60 lb in) and install hose clamp same as original hose clamp position before the rework.374F Phase Change Tank
Illustration 7 g06140762
(11) 8T-4189 Bolt
(12) 8T-4224 Hard Washer
(13) 357-4586 Elbow As
(F) 30 degree
Tighten the 8T-4189 Bolt (11) to 28 7 N m (248 62 lb in).
Assemble the 357-4586 Elbow As (13) at an angle 30 degree (F) as shown in Illustration 7 and tighten to 28 4 N m (248 35 lb in).390F Phase Change Tank
Illustration 8 g06140765
(11) 8T-4189 Bolt
(12) 8T-4224 Hard Washer
(13) 357-4586 Elbow As
(14) 468-4722 Plate As
(F) 30 degreePhase change tank and related parts are same as 374F. The difference is only support plate 468-4722 Plate As (14). Repeat the Step 1 and Step 2.Support Plate Mount
Illustration 9 g06140788
(15) 8T-4137 Bolt
(16) 7X-7729 Washer
(17) 135-8575 Bolt As (Reuse)Illustration 9 is showing example for the 374F. The different bracket is used on the 390F however the procedure is same.
Tighten the 8T-4137 Bolt (15) to 100 20 N m (74 15 lb ft).
Tighten the 135-8575 Bolt As (17) to 100 20 N m (74 15 lb ft).Software
Download the latest software from SIS Web. Refer Illustration 10 for flash software download.
Illustration 10 g06140790Tune Value Update
Illustration 11 g06140791Update threshold to 525 °C using Cat Electronic Technician (Cat ET) as shown in Illustration 11. Factory password is required to change the value. When you input your CWS ID, the factory password can be provided.