101603-2031 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032031 220204120b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-2031 1016032031

HINO 220204120B 220204120b

Service parts 101603-2031 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5200

3. GOVERNOR 105401-0580

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS 105614-3530

6. COUPLING PLATE 105662-1280

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6750

11. Nozzle and Holder 23600-2490A

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

13. NOZZLE-HOLDER 105030-4440

14. NOZZLE 105015-9220

15. NOZZLE SET

Include in #1:

101603-2031 as INJECTION-PUMP ASSEMBLY

107692-1151 as _

Cross reference number

ZEXEL 101603-2031 1016032031

HINO 220204120B 220204120b

Zexel num

Bosch num

Firm num

Name

101603-2031
101603-2032

220204120B HINO

INJECTION-PUMP ASSEMBLY
H07C-T * 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 4.8 4.77 4.83

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 11.5

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 120 118.5 121.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 35.3 35.3

Boost pressure mmHg 265 265

Injection quantity adjustment_02

Adjusting point -

Rack position 6.3

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10 9 11

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

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

Boost compensator adjustment

Pump speed r/min 725 725 725

Rack position 10.3

Boost pressure kPa 8.7 6 11.4

Boost pressure mmHg 65 45 85

Boost compensator adjustment_02

Pump speed r/min 725 725 725

Rack position (11.5)

Boost pressure kPa 22 15.3 28.7

Boost pressure mmHg 165 115 215

Timer adjustment

Pump speed r/min 850--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 800

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Notch fixed: K (2)Tolerance for racks not indicated: +-0.05mm. (3)Set idle sub-spring (4)Boost compensator stroke (5)Main spring setting
----------
K=17
----------

Speed control lever angle

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

----------
a=(17deg)+-5deg b=(28deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Speed = aa, rack position = bb (sealed at shipping)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)