101603-2112 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032112 220008361d

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-2112 1016032112

HINO 220008361D 220008361d

Service parts 101603-2112 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6171

3. GOVERNOR 105932-0481

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:

101603-2112 as INJECTION-PUMP ASSEMBLY

101603-8512 as _

Cross reference number

ZEXEL 101603-2112 1016032112

HINO 220008361D 220008361d

Zexel num

Bosch num

Firm num

Name

101603-2112
101603-2113

220008361D 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

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 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

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

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

N:Engine manufacturer's normal use S:Stop the pump. (1)Use the hole at R = aa (2)Rack position = bb (speed lever full, speed = cc). (3)Free (4)Set the stopper screw. (After setting, apply paint.)
----------
aa=50mm bb=16.2+-0.2mm cc=0r/min
----------
a=(40deg) b=30deg+-5deg c=10deg+-5deg d=0deg+-5deg

0000001501 LEVER

1. ASR lever adjustment (1)At pump speed N1 adjust bolt (A) so that ASR lever clearance is approx. L at full load.
----------
N1=275r/min L=2mm
----------