Information injection-pump assembly
ZEXEL
101601-5910
1016015910
HINO
220007511A
220007511a
Rating:
Cross reference number
ZEXEL
101601-5910
1016015910
HINO
220007511A
220007511a
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
131424-8320
Overflow valve opening pressure
kPa
108
88
128
Overflow valve opening pressure
kgf/cm2
1.1
0.9
1.3
Tester oil delivery pressure
kgf/cm2
157
157
157
RED3 control unit part number
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
4.3
4.27
4.33
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
-
Rack position
12.7
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
90.3
88.7
91.9
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
H
Rack position
9.5+-0.5
Pump speed
r/min
250
250
250
Each cylinder's injection qty
mm3/st.
15.4
14.4
16.4
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.7)
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
90.3
89.3
91.3
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.55
Pump speed
r/min
1450
1450
1450
Average injection quantity
mm3/st.
93.7
89.7
97.7
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
C
Rack position
R1-0.7
Pump speed
r/min
600
600
600
Average injection quantity
mm3/st.
75.7
71.7
79.7
Fixing the lever
*
Injection quantity adjustment_06
Adjusting point
I
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
136
136
146
Fixing the lever
*
Rack limit
*
Timer adjustment
Pump speed
r/min
950--
Advance angle
deg.
0
0
0
Load
1/4
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
900
Advance angle
deg.
0.3
Load
1/4
Timer adjustment_03
Pump speed
r/min
(1000)
Advance angle
deg.
1.5
1.2
1.8
Load
4/4
Remarks
Measure the actual speed.
Measure the actual speed.
Timer adjustment_04
Pump speed
r/min
1210+50
Advance angle
deg.
1.5
1.2
1.8
Load
3/4
Timer adjustment_05
Pump speed
r/min
1450-50
Advance angle
deg.
5
4.7
5.3
Load
4/4
Remarks
Finish
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=G55
----------
----------
T1=G55
----------
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=34deg+-5deg b=(45.5deg)+-3deg
----------
aa=41mm
----------
a=34deg+-5deg b=(45.5deg)+-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 bolt, confirm non-injection at speed dd. Rack position = non-injection rack position (actual measurement)
----------
aa=38mm bb=1450r/min cc=7-0.5mm dd=250r/min
----------
a=28deg+-5deg b=26deg+-5deg
----------
aa=38mm bb=1450r/min cc=7-0.5mm dd=250r/min
----------
a=28deg+-5deg b=26deg+-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)
----------
----------
a=(20deg)
Information:
This manual contains safety, operation instructions, lubrication and maintenance information.Some photographs or illustrations in this publication show details or attachments that may be different from your engine. Guards and covers may have been removed for illustrative purposes.Continuing improvement and advancement of product design may have caused changes to your engine which are not included in this publication.Read - study - and keep it handy. Whenever a question arises regarding your engine, or this publication, please consult your Caterpillar dealer for the latest available information.Safety
The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning labels used on the engine.Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.Operation
Illustrations guide the operator through correct procedures of checking, starting, operating and stopping the engine.The operation section is a reference for the new operator and a refresher for the experienced one.The operating sections outlined in this publication are organized to assist you with developing the skills and techniques required to operate your engine more efficiently and economically.Maintenance
The maintenance section is a guide to equipment care. The illustrated, step-by-step instructions are grouped by Preventive Maintenance servicing intervals. Items in the "Maintenance Management Schedule" are referenced to detailed instructions that follow.The "Maintenance Management Schedule" items are organized for a Preventive Maintenance Program.If the Preventive Maintenance Program is followed, a periodic tune-up is not required. The implementation of a Preventive Maintenance Management Program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.Maintenance Intervals
The service interval for each item listed in the "Maintenance Management Schedule" is primarily based on the item and its relationship to either engine speed or load.We recommend that these schedules be reproduced for ease of inspection. We also recommend that a maintenance record be maintained as part of the equipment's permanent record.See the "Maintenance Log" section of this publication for information regarding documents that are generally accepted as proof of maintenance or repair.Your authorized Caterpillar dealer can assist you in tailoring your schedule to meet the needs of your operating environment.
The safety section lists basic safety precautions. In addition, this section identifies the text and locations of warning labels used on the engine.Read and understand the basic precautions listed in the safety section before operating or performing lubrication, maintenance and repair on this product.Operation
Illustrations guide the operator through correct procedures of checking, starting, operating and stopping the engine.The operation section is a reference for the new operator and a refresher for the experienced one.The operating sections outlined in this publication are organized to assist you with developing the skills and techniques required to operate your engine more efficiently and economically.Maintenance
The maintenance section is a guide to equipment care. The illustrated, step-by-step instructions are grouped by Preventive Maintenance servicing intervals. Items in the "Maintenance Management Schedule" are referenced to detailed instructions that follow.The "Maintenance Management Schedule" items are organized for a Preventive Maintenance Program.If the Preventive Maintenance Program is followed, a periodic tune-up is not required. The implementation of a Preventive Maintenance Management Program should minimize operating costs through cost avoidances resulting from reductions in unscheduled downtime and failures.Maintenance Intervals
The service interval for each item listed in the "Maintenance Management Schedule" is primarily based on the item and its relationship to either engine speed or load.We recommend that these schedules be reproduced for ease of inspection. We also recommend that a maintenance record be maintained as part of the equipment's permanent record.See the "Maintenance Log" section of this publication for information regarding documents that are generally accepted as proof of maintenance or repair.Your authorized Caterpillar dealer can assist you in tailoring your schedule to meet the needs of your operating environment.