101603-2770 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032770 220206340a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-2770 1016032770

HINO 220206340A 220206340a

Cross reference number

ZEXEL 101603-2770 1016032770

HINO 220206340A 220206340a

Zexel num

Bosch num

Firm num

Name

101603-2770
101603-2771

220206340A HINO

INJECTION-PUMP ASSEMBLY
W06D-TI * 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 131424-6420

Overflow valve opening pressure kPa 255 255 255

Overflow valve opening pressure kgf/cm2 2.6 2.6 2.6

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 4.4 4.35 4.45

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point A

Rack position 12.3

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 139.5 137.5 141.5

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 70.6 70.6

Boost pressure mmHg 530 530

Injection quantity adjustment_02

Adjusting point B

Rack position 7.1+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 14.5 13 16

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position 10.4

Boost pressure kPa 20 17.3 22.7

Boost pressure mmHg 150 130 170

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 12.8

Boost pressure kPa 57.3 50.6 64

Boost pressure mmHg 430 380 480

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. 0.3

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1.5 1.2 1.8

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)Set idle sub-spring (4)Boost compensator stroke: BCL (5)Main spring setting
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K=12 BCL=2.4+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
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a=13deg+-5deg b=30deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
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aa=0r/min bb=1-0.2mm
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a=21deg+-5deg b=(55deg)

0000001501 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
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T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
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Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
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a=(70deg)