101603-2780 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032780 220206350a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-2780 1016032780

HINO 220206350A 220206350a

Service parts 101603-2780 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6820

3. GOVERNOR 105411-2580

4. SUPPLY PUMP 105210-6060

5. AUTOM. ADVANCE MECHANIS 105680-5120

6. COUPLING PLATE 105662-1520

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-8670

11. Nozzle and Holder 23600-3580A

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}

13. NOZZLE-HOLDER 105030-3700

14. NOZZLE

15. NOZZLE SET 105019-2860

Include in #1:

101402-0852 as _

101603-2780 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101603-2780 1016032780

HINO 220206350A 220206350a

Zexel num

Bosch num

Firm num

Name

101603-2780
101603-2781

220206350A HINO

INJECTION-PUMP ASSEMBLY
J08C-T * K 14BN 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 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 A

Rack position 11.4

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 133.5 131.5 135.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 34 34

Boost pressure mmHg 255 255

Injection quantity adjustment_02

Adjusting point -

Rack position 7.5+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 8 7 9

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 E

Rack position 11.6++

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 100 100 110

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 10.4

Boost pressure kPa 18 15.3 20.7

Boost pressure mmHg 135 115 155

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 10.7

Boost pressure kPa 20.7 20.7 20.7

Boost pressure mmHg 155 155 155

Timer adjustment

Pump speed r/min 600--

Advance angle deg. 0 0 0

Load 0/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 550

Advance angle deg. 0 -0.3 0

Load 0/4

Timer adjustment_03

Pump speed r/min -

Advance angle deg. -1.5 -1.8 -1.2

Load 0/4

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)RACK LIMIT (4)Boost compensator stroke (5)Rack difference between N = N1 and N = N2 (6)Idle sub spring setting: L1.
----------
K=15 N1=1050r/min N2=500r/min L1=7.8+-0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=100mm
----------
a=(7deg)+-5deg b=(23deg)+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Normal (2)Rack position = aa, speed = bb (stamp at delivery) (3)Use the hole above R = cc
----------
aa=1-0.5mm bb=0r/min cc=25mm
----------
a=21deg+-5deg b=(55deg)