101602-2321 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016022321 220203071a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-2321 1016022321

HINO 220203071A 220203071a

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Service parts 101602-2321 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3431

3. GOVERNOR 105400-5211

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105661-0410

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-5490

11. Nozzle and Holder 23600-1830

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105030-4060

14. NOZZLE 105015-7180

15. NOZZLE SET

Include in #1:

101602-2321 as INJECTION-PUMP ASSEMBLY

106673-4010 as _

Cross reference number

ZEXEL 101602-2321 1016022321

HINO 220203071A 220203071a

Zexel num

Bosch num

Firm num

Name

101602-2321
101602-2322

220203071A HINO

INJECTION-PUMP ASSEMBLY
H06CT * 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 134424-0920

Overflow valve opening pressure kPa 162 147 177

Overflow valve opening pressure kgf/cm2 1.65 1.5 1.8

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 3.95 4.05

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 9.3

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 87.1 86.1 88.1

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 6+-0.5

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 10 9 11

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 130 130 140

Fixing the lever *

Rack limit *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT (3)Set idle sub-spring (4)Main spring setting
----------
K=7
----------

Speed control lever angle

F:Full speed I:Idle S:Stop (1)Set the stopper bolt at delivery
----------

----------
a=18deg+-5deg b=15deg+-5deg c=17deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

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

----------
a=(60deg)

Information:

Table 4
Cat Specification for Biodiesel Fuel
Property Test Method Test Method Units Limits
United States International Specific Properties of Fuel
Density at 15°C "ASTM D1298" "ISO 3675" g/cm3 0.86-0.90
Viscosity at 40°C "ASTM D445" "ISO 3104" mm2/s (cSt) 1.9-6.0
Flash Point "ASTM D93" "ISO 3679" °C 93 minimum
Pour Point
- Summer
- Winter "ASTM D97" "ISO 3016" °C 6 °C (10 °F) minimum below ambient temperature
Cloud Point "ASTM D2500" °C Report
Sulfur Content "ASTM D5453" "ISO 20846"
"ISO 20884" percent weight 0.0015 maximum
Distillation
- 10 percent Evaporation
- 90 percent Evaporation "ASTM D1160" °C To Be Determined
360
Carbon Residue, Conradson (CCR) "ASTM D4530" "ISO 10370" percent weight 0.05 maximum
Cetane Number "ASTM D613" "ISO 5165" 45 minimum
Sulfated Ash "ASTM D874" "ISO 3987" percent weight 0.02 maximum
Water/Sediment Content "ASTM D2709" "ISO 12937" percent volume 0.05 maximum
Copper Corrosion "ASTM D130" "ISO 2160" No. 1
Oxidation Stability "EN 14112" "EN 14112" hours 3 minimum
Esterification "EN 14103" "EN 14103" percent volume 97.5 minimum
Acid Value "ASTM D664" "EN 14104" mg KOH/g 0.5 maximum
Methanol Content "EN 14110" "EN 14110" percent weight 0.2 maximum
Monoglycerides "ASTM D6584" "EN 14105" percent weight 0.8 maximum
Diglycerides "ASTM D6584" "EN 14105" percent weight 0.2 maximum
Triglycerides "ASTM D6584" "EN 14105" percent weight 0.2 maximum
Free Glycerin "ASTM D6584" "EN 14105" percent weight 0.02 maximum
Total Glycerin "ASTM D6584" "EN 14105" percent weight 0.240 maximum
Phosphorus Content "ASTM D4951" "EN 14107" percent weight 0.001
Calcium and Magnesium combined "EN 14538" "EN 14538" ppm 5 maximum
Sodium and Potassium combined "EN 14538" "EN 14538" ppm 5 maximum
Cold Soak Filterability "ASTM D7501" -- seconds 360 maximum
Cleanliness "ASTM D7619" "ISO 4406" -- (1)
(1) Recommended cleanliness level for fuel as dispensed into machine or engine fuel tank is "ISO 18/16/13" or cleaner per "ISO 4406" or "ASTM D7619". Refer to the “Contamination Control” section in this Special Publication.Note: Fuels that meet the most current revision level of "ASTM D6751" or "EN 14214" may be used for blending with an acceptable distillate fuel. The conditions, recommendations, and limits that are noted in this Biodiesel section apply.Referenced Documents
Refer to the “Reference Material - Fuel” section of this Special Publication for the reference material for the information in this section.