101501-2040 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1015012040 220009230a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101501-2040 1015012040

HINO 220009230A 220009230a

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Buy INJECTION-PUMP ASSEMBLY 101501-2040 zexel genuine, new aftermarket engine parts with delivery

Service parts 101501-2040 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101050-0070

3. GOVERNOR 105932-1870

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 23600-2663C

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:

101501-2040 as INJECTION-PUMP ASSEMBLY

Include in #2:

104761-4092 as _

Cross reference number

ZEXEL 101501-2040 1015012040

HINO 220009230A 220009230a

Zexel num

Bosch num

Firm num

Name

101501-2040
101501-2041

220009230A 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

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=L71
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=41mm
----------
a=8deg+-5deg b=(39deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). 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=1580r/min cc=6.8-0.5mm dd=300r/min
----------
a=0deg+-5deg b=(28deg)+-5deg

Timing setting

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

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

Information:

Please consult SISWEB for serial number prefix specific details.
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Please consult the appropriate Cat parts warranty statement for your area.
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INFORMATION RELEASE MEMO | PAGE 4
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