101603-2101 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032101 220008350b

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-2101 1016032101

HINO 220008350B 220008350b

Cross reference number

ZEXEL 101603-2101 1016032101

HINO 220008350B 220008350b

Zexel num

Bosch num

Firm num

Name

101603-2101
101603-2102

220008350B 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 12.5

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 105 103 107

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(12.5)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 105 104 106

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.75

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 107 103 111

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.85 )

Pump speed r/min 580 580 580

Average injection quantity mm3/st. 96.5 92.5 100.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point D

Rack position R1+0.3

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 105.5 101.5 109.5

Fixing the lever *

Injection quantity adjustment_07

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 145 145 155

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=J66
----------

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=36deg+-3deg

Stop lever angle

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

Timing setting

(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 101603-2101?

Group cross 101603-2101 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