101603-2062 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032062 220204342a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-2062 1016032062

HINO 220204342A 220204342a

Service parts 101603-2062 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5310

3. GOVERNOR 105401-0631

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS 105614-3660

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:

101603-2062 as INJECTION-PUMP ASSEMBLY

101603-8472 as _

Cross reference number

ZEXEL 101603-2062 1016032062

HINO 220204342A 220204342a

Zexel num

Bosch num

Firm num

Name

101603-2062
101603-2063

220204342A HINO

INJECTION-PUMP ASSEMBLY
H07C-T * K 14BF PE6AD 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 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 10.9

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 99 97.5 100.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_02

Adjusting point -

Rack position 6.3+-0.5

Pump speed r/min 495 495 495

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.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 130 130 140

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position 11.3

Boost pressure kPa 13.3 10.6 16

Boost pressure mmHg 100 80 120

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 12

Boost pressure kPa 21.3 21.3 21.3

Boost pressure mmHg 160 160 160

Timer adjustment

Pump speed r/min (N1+50)- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min N1

Advance angle deg. 0.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 2 1.5 2.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Set idle sub-spring (5)Boost compensator stroke (6)Rack difference between N = N1 and N = N2 (7)Main spring setting
----------
K=10 N1=1100r/min N2=500r/min
----------

Speed control lever angle

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

----------
a=5deg+-5deg b=23deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Speed = aa, rack position = bb (sealed at shipping)
----------
aa=0r/min bb=1-0.2mm
----------
a=21deg+-5deg b=(55deg)