Information injection-pump assembly
ZEXEL
101601-2430
1016012430
HINO
220002280B
220002280b
Rating:
Cross reference number
ZEXEL
101601-2430
1016012430
HINO
220002280B
220002280b
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
1-4-2-6-
3-5
Pre-stroke
mm
3.1
3.05
3.15
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
10.6
Pump speed
r/min
1000
1000
1000
Average injection quantity
mm3/st.
68.6
67.6
69.6
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Injection quantity adjustment_02
Adjusting point
B
Rack position
10.6
Pump speed
r/min
1500
1500
1500
Average injection quantity
mm3/st.
68.5
67
70
Max. variation between cylinders
%
0
-5
5
Fixing the lever
*
Injection quantity adjustment_03
Adjusting point
C
Rack position
8.9+-0.5
Pump speed
r/min
275
275
275
Average injection quantity
mm3/st.
8
7
9
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Timer adjustment
Pump speed
r/min
1000++
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1250
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1400
Advance angle
deg.
2
1.5
2.5
Timer adjustment_04
Pump speed
r/min
1500
Advance angle
deg.
3.5
3
4
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: none
(2)RACK LIMIT
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Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
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a=30deg+-5deg b=41deg+-3deg
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a=30deg+-5deg b=41deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
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a=5deg+-5deg b=40deg+-5deg
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a=5deg+-5deg b=40deg+-5deg
0000001501 MICRO SWITCH
Switch adjustment
Adjust the bolt so that the lower lever position is obtained when the switch is turned ON.
(1)Speed N1
(2)Rack position Ra
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N1=375-25r/min Ra=9.2mm
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N1=375-25r/min Ra=9.2mm
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Information:
2. Disconnect hose assemblies (2) and (4) from BrakeSaver control valve (1).3. Remove the bolts that hold elbow (3) and tube assembly (5) to BrakeSaver control valve (1). 4. Remove the four bolts (6) and remove BrakeSaver control valve (1) from the engine.Install Brakesaver Control Valve
1. Install O-ring seals (2) in BrakeSaver control valve (1).2. Make sure the seals are in position in the tube assembly and elbow.3. Put BrakeSaver control valve (1) in position on the engine and install the four bolts and lockwashers that hold it. 4. Install the bolts that hold tube assembly (6) and elbow (3) to the BrakeSaver control valve.5. Connect hose assemblies (4) and (5) to the BrakeSaver control valve.6. Fill the engine with oil to the correct level. Disassemble Brakesaver Control Valve
start by: a) remove BrakeSaver control valve 1. Remove plug (1), the O-ring seal, spring and plunger from the valve body. 2. Remove the bolts that hold cover (2) and valve group (10) in position. Remove cover (2), O-ring seal (3), valve group (10), gasket (9), slug (8), spring (7), stop (6), spring (5) and valve spool (4) from the valve body.3. Disassemble valve group (10) as follows: a) Remove the two plugs and O-ring seals from the ends of the valve body.b) Remove the two slugs and valve spool from the valve body.Assemble Brakesaver Control Valve
1. Install valve spool (3), slugs (2) and (5), the O-ring seals and plugs (1) and (6) in valve body (4) as shown. 2. Install the plunger, spring, O-ring seal and plug (16) in valve body (9).3. Install O-ring seal (8) and cover (7) on valve body (9).4. Install valve spool (10), spring (11), stop (12), spring (13) and slug (14) in valve body (9).5. Put gasket (15) and valve body (4) in position on valve body (9) and install the bolts to hold it.end by: a) install BrakeSaver control valve
1. Install O-ring seals (2) in BrakeSaver control valve (1).2. Make sure the seals are in position in the tube assembly and elbow.3. Put BrakeSaver control valve (1) in position on the engine and install the four bolts and lockwashers that hold it. 4. Install the bolts that hold tube assembly (6) and elbow (3) to the BrakeSaver control valve.5. Connect hose assemblies (4) and (5) to the BrakeSaver control valve.6. Fill the engine with oil to the correct level. Disassemble Brakesaver Control Valve
start by: a) remove BrakeSaver control valve 1. Remove plug (1), the O-ring seal, spring and plunger from the valve body. 2. Remove the bolts that hold cover (2) and valve group (10) in position. Remove cover (2), O-ring seal (3), valve group (10), gasket (9), slug (8), spring (7), stop (6), spring (5) and valve spool (4) from the valve body.3. Disassemble valve group (10) as follows: a) Remove the two plugs and O-ring seals from the ends of the valve body.b) Remove the two slugs and valve spool from the valve body.Assemble Brakesaver Control Valve
1. Install valve spool (3), slugs (2) and (5), the O-ring seals and plugs (1) and (6) in valve body (4) as shown. 2. Install the plunger, spring, O-ring seal and plug (16) in valve body (9).3. Install O-ring seal (8) and cover (7) on valve body (9).4. Install valve spool (10), spring (11), stop (12), spring (13) and slug (14) in valve body (9).5. Put gasket (15) and valve body (4) in position on valve body (9) and install the bolts to hold it.end by: a) install BrakeSaver control valve