101601-2850 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016012850 220801221b

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-2850 1016012850

HINO 220801221B 220801221b

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Cross reference number

ZEXEL 101601-2850 1016012850

HINO 220801221B 220801221b

Zexel num

Bosch num

Firm num

Name

101601-2850

220801221B HINO

INJECTION-PUMP ASSEMBLY
H07C * 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 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 6.9

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 65 64 66

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 5+-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.

Injection quantity adjustment_03

Adjusting point E

Rack position 7.2+-0.5

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 56 54 58

Fixing the lever *

Timer adjustment

Pump speed r/min 1250

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 1.5 1 2

Timer adjustment_03

Pump speed r/min 1430

Advance angle deg. 4.5 4.2 4.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)RACK LIMIT (2)Automatic idle adjustment, adjust using dial. (3)Set using full load set screw.
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Stop lever angle

N:Pump normal S:Stop the pump.
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a=(10.5deg) b=(33deg)

Timing setting

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

----------
a=(60deg)

Information:

Recommended Procedure A. MISFIRING AND RUNNING ROUGHSee the chart, Misfiring and Running Rough. B. PROBLEM WITH VEHICLE or VEHICLE OPERATIONSee the chart, Problem With Vehicle or Vehicle Operation. C. LOW ENGINE RPM1. Governor Linkage Disconnect the governor linkage at the lever on the governor. Move the governor lever by hand until the linkage inside the governor is against the high idle stop. With the accelerator pedal all the way down, adjust the linkage so that the inside linkage is against the high idle stop. Some trucks are equipped with linkage which has spring force and some are equipped with a governor lever of the break over type. On engines with either of these, adjust the governor linkage .250 in. (6,35 mm) longer than necessary for the inside linkage to be against the high idle stop, this will keep tension on the spring at all times. For trucks with tilt cabs, do not make this check with the cab tilted.2. Governor High Idle Adjustment If the governor linkage moves the governor lever to the fully open position, check the high idle rpm with a good tachometer. If the high idle rpm is too low, turn the high idle adjustment screw counterclockwise until high idle rpm is correct. See the RACK SETTING INFORMATION for the correct high idle rpm. If high idle rpm can not be made correct with the high idle adjustment screw, there is a problem inside the governor. Disassemble the governor and check for damage to parts or the wrong parts installed in the governor. D. NOT ENOUGH AIR3. Inlet Restriction Air inlet restriction will cause low power and too much smoke when under load. Check for a restriction with a water manometer or a vacuum gauge (which measures in inches of water). Connect the gauge to the engine air inlet between the air cleaner and the engine. With gauge installed, run engine at full load rpm and check the restriction. Maximum restriction of the air inlet is 30 inches (762 mm) of water. If the indication is higher than the maximum permissible restriction, remove dirt from the filter element or install a new filter element and check the restriction again. If the indication is still too high, there must be a restriction in the inlet piping.4. Exhaust Restriction Make a visual inspection of the exhaust system and look for damage to piping or for a bad muffler. If no damage is found, you can also check the system by removing the exhaust pipes from the exhaust manifolds. With the exhaust pipes removed, start and run the engine to see if the problem is corrected. E. LOW QUALITY FUEL5. Water in Fuel Remove a small amount of fuel from the tank and check for water in the fuel. If there is water in the fuel, remove fuel from tank until it is free of water. Install a new fuel filter and fill the fuel tank with clean fuel. "Prime" (remove the air and/or low quality fuel