101603-2020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032020 220008070a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-2020 1016032020

HINO 220008070A 220008070a

Service parts 101603-2020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9550

3. GOVERNOR 105921-6320

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0860

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5161

11. Nozzle and Holder 23600-2142A

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-8241

15. NOZZLE SET

Include in #1:

101603-2020 as INJECTION-PUMP ASSEMBLY

101603-8342 as _

Cross reference number

ZEXEL 101603-2020 1016032020

HINO 220008070A 220008070a

Zexel num

Bosch num

Firm num

Name

101603-2020
101603-2021

220008070A HINO

INJECTION-PUMP ASSEMBLY
W06E A * K 14BE PE6A PE

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 3.45 3.42 3.48

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 -

Rack position 11.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 58.8 56.8 60.8

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 9.3+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 17.1 16.1 18.1

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.2)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 58.8 57.8 59.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(11.2)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 59.3 55.3 63.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.3

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 53.7 49.7 57.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 123 123 133

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 2.5 2.2 2.8

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=H37
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=55mm
----------
a=(27deg)+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Set the stopper bolt. (After setting, apply red paint.)
----------
aa=17+-0.1mm
----------
a=(35deg) b=40deg+-5deg c=40deg+-5deg

0000001501 TAMPER PROOF

1. Method for setting tamperproof proofing (1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to Ra. (2)At pump speed N1, push in the screw (A) until the rack position is Rb. (3)Temporarily caulk using the tip of a screwdriver (4)Confirm that the rack at that time is at Rc. (5)Lock using setscrew (B). (Tightening torque = T) (6)Next, coat (C) with adhesive and then pressfit. (7)Then, readjust the full rack position using the load lever.
----------
N1=1500r/min Ra=R1(11.2)+0.4mm Rb=R1(11.2)+0.4mm Rc=R1(11.2)+0.4mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)