101603-2020 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032020 220008070a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-2020 1016032020

HINO 220008070A 220008070a

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Service parts 101603-2020 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9550

3. GOVERNOR 105921-6320

4. SUPPLY PUMP 105220-5300

5. AUTOM. ADVANCE MECHANIS 105676-0860

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-5161

11. Nozzle and Holder 23600-2142A

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

13. NOZZLE-HOLDER 105041-5041

14. NOZZLE 105015-8241

15. NOZZLE SET

Include in #1:

101603-2020 as INJECTION-PUMP ASSEMBLY

101603-8342 as _

Cross reference number

ZEXEL 101603-2020 1016032020

HINO 220008070A 220008070a

Zexel num

Bosch num

Firm num

Name

101603-2020
101603-2021

220008070A HINO

INJECTION-PUMP ASSEMBLY
W06E A * K 14BE PE6A 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 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 3.45 3.42 3.48

Beginning of injection position
Drive 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 11.2

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 58.8 56.8 60.8

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 H

Rack position 9.3+-0.5

Pump speed r/min 250 250 250

Each cylinder's injection qty mm3/st. 17.1 16.1 18.1

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.2)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 58.8 57.8 59.8

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1(11.2)

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 59.3 55.3 63.3

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.3

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 53.7 49.7 57.7

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 123 123 133

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1050--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1000

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 2.5 2.2 2.8

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=H37
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=55mm
----------
a=(27deg)+-3deg b=34deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Set the stopper bolt. (After setting, apply red paint.)
----------
aa=17+-0.1mm
----------
a=(35deg) b=40deg+-5deg c=40deg+-5deg

0000001501 TAMPER PROOF

1. Method for setting tamperproof proofing (1)After governor adjustment (torque cam phase adjustment), move the load lever to increase the full rack position to Ra. (2)At pump speed N1, push in the screw (A) until the rack position is Rb. (3)Temporarily caulk using the tip of a screwdriver (4)Confirm that the rack at that time is at Rc. (5)Lock using setscrew (B). (Tightening torque = T) (6)Next, coat (C) with adhesive and then pressfit. (7)Then, readjust the full rack position using the load lever.
----------
N1=1500r/min Ra=R1(11.2)+0.4mm Rb=R1(11.2)+0.4mm Rc=R1(11.2)+0.4mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)

Timing setting

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

----------
a=(70deg)

Information:

789 Truck
On the 789 Truck, there are two mounting plates and two sets of ether nozzles, both of which are mounted on the frame cross tube in the engine compartment. 1. Install 8X0913 Tube (63) in the front nozzle, and 8W8177 Tube (65) in the rear nozzle of the front pair of turbocharger outlet adapters as shown.2. Use two 5P6314 Sleeves with 5P6313 Nuts to connect tubes (63) and (65) to 8C9006 Tee (64).3. Put 8X5015 Tube (60) in position along the cylinder block and frame cross tube (59). Use a 5P6314 Sleeve and a 5P6313 Nut to connect tube (60) to 8C9006 Tee (64) as shown.4. Connect one end of a 7N0140 Tube Assembly in the bottom of the shuttle valve on the right side mounting plate (62) to the free end of 8X5015 Tube (60).5. Use three 6V2686 Clips (61), with existing bolts on the engine cylinder block and truck frame cross tube (59), to secure 8X5015 Tube (60) as shown.6. Install 8W8179 Tube (66) in the front nozzle and 8W8180 Tube (67) in the rear nozzle of the rear pair of turbocharger outlet adapters as shown.7. Use two 5P6314 Sleeves with 5P6313 Nuts to connect tubes (66) and (67) to 8C9006 Tee (68).8. Use two 6V2686 Clips (61) with existing bolts to secure 8W8180 Tube (67) to the engine block as shown.9. Put 8W8178 Tube (69) in position along the cylinder block and connect it to 8C9006 Tee (68) as shown using a 5P6314 Sleeve and 5P6313 Nut.10. Connect one end of a 7N0140 Tube Assembly in the bottom connector of the shuttle valve on left side mounting plate (70) to the free end of the 8W8178 Tube (69).11. Use three 6V2686 Clips (61) with existing bolts on engine cylinder block to secure 8W8178 Tube (69) as shown.Installation of Ether Cylinders
1. Turn the disconnect switch to the ON position and put the start switch key in the OFF position. Make sure the two lamps on the console and the two yellow LEDs on the ECU are flashing.If they are flashing, it indicates that the control is functioning and recognizes that no ether cylinders are installed.2. Inspect the two digit, seven segment LED display on the ECU. It must read "00". This in an indication that there are no faults.If the display does not read "00", refer to the Service Manual, SENR4705, for a troubleshooting procedure of the system. 3. Remove protective caps (71) and (72) from 9X7137 Ether Solenoid Valves (73) and (74) (left side ether assembly mounting plate on 789 Truck when viewed from the rear of the engine). Install a new 9X7138 Filter Assembly in each solenoid valve inlet if one is not already in place.4. Install a 9X0147 Collar on the neck of each new 7X1062 Ether Cylinder.5. Remove the protective plug from the end of the new FULL ether cylinder, then install the new ether cylinder for ether