101601-2520 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016012520 220002450a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-2520 1016012520

HINO 220002450A 220002450a

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Cross reference number

ZEXEL 101601-2520 1016012520

HINO 220002450A 220002450a

Zexel num

Bosch num

Firm num

Name

101601-2520
101601-2521

220002450A HINO

INJECTION-PUMP ASSEMBLY
EH700 *

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 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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.1 3.07 3.13

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point A

Rack position 6.6

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 65.6 64.6 66.6

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.6

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 65.5 64 67

Max. variation between cylinders % 0 -5 5

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 5.2+-0.5

Pump speed r/min 375 375 375

Average injection quantity mm3/st. 8 7 9

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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

Timer adjustment

Pump speed r/min 1350

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1400

Advance angle deg. 1.5

Timer adjustment_03

Pump speed r/min 1600

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting
----------
K=10
----------

Speed control lever angle

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

----------
a=58deg+-5deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=0deg+-5deg b=53deg+-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
----------
N1=375-25r/min Ra=5.5mm
----------

Information:

Section A:
Rotation (seen from the drive end) ... counterclockwise Test on test stand, with SAE 10W oil at 120° F (49° C) Output ... 51 U.S. gpm(193 liter/min) with pump at ... 2550 rpmSection B:
Rotation (seen from the drive end) ... counterclockwise Test on test stand, with SAE 10W oil at 120° F (49° C) Output ... 72 U.S. gpm(272 liter/min) at a pressure of ... 45 psi(310 kPa)with pump at ... 2550 rpmOutput ... 38 U.S. gpm(144 liter/min) at a pressure of ... 81 psi(560 kPa)with pump at ... 2550 rpm Scavenge pump end (Section A)(1) Diameter of drive shaft and idler shaft (new) ... .8000 .0002 in.(20.320 0.005 mm) Bore in bearings for drive shaft and idler shaft (new) ... .8016 .0003 in.(20.361 0.008 mm)(2) Length of gears (new) ... 2.2503 .0010 in.(57.158 0.025 mm) Depth of bores for gears (new) ... 2.2553 .0008 in.(57.285 0.020 mm) Spacer assembly(3) Diameter of drive shaft and idler shaft (new) ... .8747 .0002 in.(22.217 0.005 mm) Bore in bearings for drive shaft and idler shaft (new) ... .8763 .0003 in.(22.258 0.008 mm) Pump body assembly (Section B)(4) Length of gears (new) ... 3.1250 .0010 in.(79.375 0.025 mm) Depth of bores for gears (new) ... 3.1300 .0008 in.(79.502 0.020 mm)(5) Diameter of drive shaft and idler shaft (new) ... .8747 .0002 in.(22.217 0.005 mm) Bore in bearings for drive shaft and idler shaft (new) ... .8763 .0003 in.(22.258 0.008 mm)(6) 2S2760 Spring (oil pressure relief valve): Length under test force ... 4.64 in.(117.9 mm)Test force ... 110 6 lb.(490 27 N)Free length after test ... 6.02 in.(152.9 mm)Outside diameter ... 1.063 in.(27.00 mm)
SCAVENGE PUMP(7) Bearing junction.(8) Position of bearing junction from the centerline through bearing bores ... 30° 15°(9) Install bearings in bottom of gear bores to a depth of ... .060 .010 in.(1.52 0.25 mm) Rotation of pump must be free when turned by hand.