101501-2021 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1015012021 220008710b


 

Information injection-pump assembly

ZEXEL 101501-2021 1015012021
HINO 220008710B 220008710b
101501-2021 INJECTION-PUMP ASSEMBLY
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Service parts 101501-2021 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101050-0070
3. GOVERNOR 105932-0691
4. SUPPLY PUMP 105210-6060
5. AUTOM. ADVANCE MECHANIS 105672-5270
6. COUPLING PLATE 105662-1520
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-7705
11. Nozzle and Holder 23600-2663
12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}
13. NOZZLE-HOLDER 105030-3601
14. NOZZLE
15. NOZZLE SET 105019-0314

Include in #1:

101501-2021 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101501-2021 1015012021
HINO 220008710B 220008710b


Zexel num
Bosch num
Firm num
Name
101501-2021 
101501-2022 
 
220008710B  HINO
INJECTION-PUMP ASSEMBLY
J07C * K

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil
  ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8250
Bosch type code   1 688 901 101
Nozzle   105780-0120
Bosch type code   1 688 901 990
Nozzle holder   105780-2190
Opening pressure MPa   20.7
Opening pressure kgf/cm2   211
Injection pipe
Outer diameter - inner diameter - length (mm)
mm   6-2-600
Overflow valve   131425-0320
Overflow valve opening pressure kPa   108 88 128
Overflow valve opening pressure kgf/cm2   1.1 0.9 1.3
Tester oil delivery pressure kPa   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
Direction of rotation (viewed from drive side)
Left
  L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left
  L
Injection order   1-2-4-5- 3
Pre-stroke mm   4 3.97 4.03
Beginning of injection position
Governor side
  NO.1
Difference between angles 1
Cyl.1-2
deg.   72 71.75 72.25
Difference between angles 2
Cal 1-4
deg.   144 143.75 144.25
Difference between angles 3
Cal 1-5
deg.   216 215.75 216.25
Difference between angles 4
Cal 1-3
deg.   288 287.75 288.25
Injection quantity adjustment
Adjusting point   -
Rack position   12.2
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   100 98.4 101.6
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   Z
Rack position   9.5+-0.5
Pump speed r/min   415 415 415
Each cylinder's injection qty mm3/st.   12 11 13
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.2)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   100 99 101
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.6
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   103 99 107
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.45
Pump speed r/min   1160 1160 1160
Average injection quantity mm3/st.   105.5 101.5 109.5
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1-0.75
Pump speed r/min   580 580 580
Average injection quantity mm3/st.   84 80 88
Fixing the lever   *
Injection quantity adjustment_07
Adjusting point   E
Rack position   R1-0.9
Pump speed r/min   300 300 300
Average injection quantity mm3/st.   77 71 83
Fixing the lever   *
Injection quantity adjustment_08
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   170 170 180
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   950--
Advance angle deg.   0 0 0
Load   1/5
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   900
Advance angle deg.   0.3
Load   1/5
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   1 0.7 1.3
Load   5/5
Remarks
Measure the actual speed.
 
Timer adjustment_04
Pump speed r/min   1190++
Advance angle deg.   1 0.7 1.3
Load   2/5
Timer adjustment_05
Pump speed r/min   (1300-50 )
Advance angle deg.   1 0.7 1.3
Load   5/5
Remarks
Measure the actual speed.
 
Timer adjustment_06
Pump speed r/min   1450-50
Advance angle deg.   5.5 5.2 5.8
Load   5/5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101501-2021
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=K70
----------

Speed control lever angle

Test data 101501-2021
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=41mm
----------
a=8deg+-5deg b=(47deg)+-3deg

Stop lever angle

Test data 101501-2021
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt so that speed = bb and rack position = cc. Confirm non-injection. (3)After setting the stopper screw, confirm non-injection at N = dd and R = actual rack position. After setting apply red paint.
----------
aa=38mm bb=1750r/min cc=6.8-0.5mm dd=300r/min
----------
a=0deg+-5deg b=(28deg)+-5deg

Timing setting

Test data 101501-2021
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(20deg)




Information:


REM08-21
Reman
August 2008 INTRODUCING REMAN INJECTOR KITS FOR 3406E, C-15 AND C-16 ON-HIGHWAY TRUCK ENGINES Announcement The Caterpillar Remanufactured Products Group announces two new Cat Reman injector kit options for 3406E, C-15 and C-16 on-highway truck engine applications. Cat Reman injector kits come complete with a full set of six Cat Reman fuel injectors and o-rings. CoverageCat Reman injector kits provide dealers with the option to purchase all six injectors together in one kit with one part number. Dealers who stock Cat Reman kits have the opportunity to improve their parts and service sales by having the right amount of inventory on the shelf and ready for both planned and unplanned injector repairs and Cat engine overhauls.Order and stock Cat Reman injector kits today and have peace of mind that your dealership has the right products in inventory to offer customers a wide variety of service repair options. The table below lists coverage based upon the new Cat injector part number.
* Each kit contains six individual injectors and o-rings. Features and BenefitsCat? Remanufactured Components offer your customers excellent value. Customers who want fast repair turn-around, superior quality and reliability, and lower repair costs will benefit from the use of Cat Reman injector kits. Cat Remanufactured Components provide immediate, off-the-shelf availability at a fraction of the new price. Cat Reman injector kits offer Cat engine users many benefits. Customers save time by installing all injectors in just one trip to the shop instead of making multiple trips to install injectors one or two at a time. Customers save money by eliminating redundant labor costs and time off the road due to multiple trips to the shop to replace injectors only when they fail.In addition to saving time and money, customers who install the Cat Reman injector kit will maximize their engine performance, optimize fuel economy and restore the operation of their Cat 3406E, C-15 and C-16 engines for years to come.
Features Benefits
All critical engineering changes and updates included
Improved reliability and performance
Worldwide availability through Caterpillar? parts distribution system
Customer access regardless of location
Backed by Cat parts warranty
Consistent support
Core AcceptanceCore Acceptance Criteria for Caterpillar Remanufactured Components is simple, visual and requires no special tools. Consult your Unit Injector Electronic Core Acceptance Criteria SELD0226-01 for complete details. The purchase of a Reman Kit establishes core entitlements at the consist part level quantity. For example, purchase of a kit of six Reman Injectors establishes six individual core injector entitlements. WarrantyPlease consult the appropriate Cat parts warranty statement for your area. Return Status and Kit AvailabilityCat Reman injector kits are available when and where you need them most - the Cat parts distribution system. These Cat Reman injector kit product offerings will be stocked throughout the Cat distribution system and ready to fill dealer stock and emergency orders. Once on your shelf, dealers will now have the opportunity to promote the benefits of replacing a customer's old set of injectors with one Cat Reman injector kit. To ensure that

Have questions with 101501-2021?





Group cross 101501-2021 ZEXEL

Hino 

 
220008710A 
INJECTION-PUMP ASSEMBLY
J07C
101501-2021  

101501-2022 
 
220008710B 
INJECTION-PUMP ASSEMBLY
J07C
 
220008711B 
INJECTION-PUMP ASSEMBLY
J07C
 
 
INJECTION-PUMP ASSEMBLY

Hino 

 
220008711C 
INJECTION-PUMP ASSEMBLY
J07C
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