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101603-2102 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032102 220008350d


101603-2102 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-2102 1016032102
HINO 220008350D 220008350d

Service parts 101603-2102 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-6171
3. GOVERNOR 105932-0471
4. SUPPLY PUMP 105210-6060
5. AUTOM. ADVANCE MECHANIS 105680-5010
6. COUPLING PLATE 105662-1460
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-7705
11. Nozzle and Holder 23600-2663C
12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}
13. NOZZLE-HOLDER 105030-3601
14. NOZZLE
15. NOZZLE SET 105019-0314

Include in #1:

101603-2102 as INJECTION-PUMP ASSEMBLY
101603-8501 as _

Cross reference number

ZEXEL 101603-2102 1016032102
HINO 220008350D 220008350d


Zexel num
Bosch num
Firm num
Name
101603-2102 
101603-2103 
 
220008350D  HINO
INJECTION-PUMP ASSEMBLY
J-2 * K

Calibration Data:

Adjustment conditions
Test oil
1404 Test oil   ISO4113 or {SAEJ967d}
Test oil temperature degC   40 40 45
Nozzle and nozzle holder   105780-8250
Bosch type code   1 688 901 101
Nozzle   105780-0120
Bosch type code   1 688 901 990
Nozzle holder   105780-2190
Opening pressure MPa   20.7
Opening pressure kgf/cm2   211
Injection pipe
Outer diameter - inner diameter - length (mm) mm   6-2-600
Overflow valve   131425-0620
Overflow valve opening pressure kPa   255 221 289
Overflow valve opening pressure kgf/cm2   2.6 2.25 2.95
Tester oil delivery pressure kPa   255 255 255
Tester oil delivery pressure kgf/cm2   2.6 2.6 2.6
Direction of rotation (viewed from drive side)
Left   L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left   L
Injection order   1-4-2-6- 3-5
Pre-stroke mm   3.8 3.77 3.83
Beginning of injection position
Governor 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   12.4
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   104.5 102.5 106.5
Difference in delivery mm3/st.   0 -3.5 3.5
Basic   *
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_02
Adjusting point   Z
Rack position   9.5+-0.5
Pump speed r/min   375 375 375
Each cylinder's injection qty mm3/st.   13 12 14
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(12.4)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   104.5 103.5 105.5
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.9
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   109.5 105.5 113.5
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1+0.55
Pump speed r/min   1160 1160 1160
Average injection quantity mm3/st.   109 105 113
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   100 100 100
Average injection quantity mm3/st.   140 140 150
Fixing the lever   *
Rack limit   *
Timer adjustment
Pump speed r/min   950--
Advance angle deg.   0 0 0
Load   1/5
Remarks
Start  
Timer adjustment_02
Pump speed r/min   900
Advance angle deg.   0.3
Load   1/5
Timer adjustment_03
Pump speed r/min   -
Advance angle deg.   1.25 0.95 1.55
Load   5/5
Remarks
Measure the actual speed.  
Timer adjustment_04
Pump speed r/min   (1190++)
Advance angle deg.   1.25 0.95 1.55
Load   2/5
Remarks
Measure the actual speed.  
Timer adjustment_05
Pump speed r/min   1255-50
Advance angle deg.   1.25 0.95 1.55
Load   5/5
Timer adjustment_06
Pump speed r/min   1420-50
Advance angle deg.   5.5 5.2 5.8
Load   5/5
Remarks
Finish  

Test data Ex:

Governor adjustment

Test data 101603-2102
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=K30
----------

Speed control lever angle

Test data 101603-2102
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=46mm
----------
a=6deg+-5deg b=39deg+-3deg

Stop lever angle

Test data 101603-2102
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=38mm
----------
a=0deg+-5deg b=40deg+-5deg

Timing setting

Test data 101603-2102
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(20deg)




Have questions with 101603-2102?





Group cross 101603-2102 ZEXEL

Hino 

101603-2100  

101603-2101 
9 400 619 759 
220008350A 
INJECTION-PUMP ASSEMBLY
J-2
101603-2101  

101603-2102 
 
220008350B 
INJECTION-PUMP ASSEMBLY
J-2
101603-2102  

101603-2103 
 
220008350D 
INJECTION-PUMP ASSEMBLY
J-2
101603-2103  

101603-2104 
 
220008351A 
INJECTION-PUMP ASSEMBLY
101603-2103  

101603-2104 
 
220008351B 
INJECTION-PUMP ASSEMBLY
101603-2104  

101603-2105 
F 01G 09U 03G 
 
INJECTION-PUMP ASSEMBLY

Hino 

101603-2105  
F 019 Z10 110 
220008351C 
INJECTION-PUMP ASSEMBLY
J-2
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