101603-2061 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032061 220204341a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-2061 1016032061

HINO 220204341A 220204341a

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Cross reference number

ZEXEL 101603-2061 1016032061

HINO 220204341A 220204341a

Zexel num

Bosch num

Firm num

Name

101603-2061
101603-2062

220204341A HINO

INJECTION-PUMP ASSEMBLY
H07C-T * 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 4.8 4.77 4.83

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 A

Rack position 9.5

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 85.5 84 87

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 36 36

Boost pressure mmHg 270 270

Injection quantity adjustment_02

Adjusting point -

Rack position 6.4+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10 9 11

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.

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position 9.9

Boost pressure kPa 14.7 12 17.4

Boost pressure mmHg 110 90 130

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position 10.5

Boost pressure kPa 22.7 22.7 22.7

Boost pressure mmHg 170 170 170

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. 0.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 2 1.5 2.5

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)Main spring setting (4)Set idle sub-spring (5)Boost compensator stroke: BCL (6)Rack difference between N = N1 and N = N2
----------
K=16 BCL=0.6+-0.1mm N1=1100r/min N2=600r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=12deg+-5deg b=24deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Speed = aa, rack position = bb (sealed at shipping)
----------
aa=0r/min bb=1-0.2mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

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

----------
a=(50deg)

Information:

6N9294 Alternator Group, 3T6352 Alternator 24V 35A
Load the battery with a carbon pile (4C4911 Battery Load Tester) to get the maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output voltage ... 27.5 1.0VOutput (cold) ... 35A(1) Torque for the ground terminal nut ... 2.3 0.6 N m (21 5 lb in)(2) Torque for the pulley nut ... 102 7 N m (76 5 lb ft)(3) Torque for the output terminal nut ... 7.1 0.9 N m (64 8 lb in)3T6353 Regulator (Inside Alternator)
Voltage setting ... No adjustmentPermissible voltage range ... 26 to 30V5S9088 Alternator Group, 3T1888 Alternator 24V 50A
Load the battery with a carbon pile (4C4911 Battery Load Tester) to get the maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output (cold) ... 50A(1) Torque for the pulley nut ... 102 7 N m (76 5 lb ft)(2) Torque for the output terminal nut ... 13.5 1.3 N m (120 12 lb in)7N0129 Regulator (Inside Alternator)
Voltage setting range ... 27.5 1.0VAdjust voltage setting to ... 28V6N9294 Alternator Group, 7N9720 Alternator 24V 35A
Load the battery with a carbon pile (4C4911 Battery Load Tester) to get the maximum alternator output.Polarity ... Negative GroundRotation ... ClockwiseSpeed for testing (rpm) ... 5000Output voltage ... 27.5 1.0VOutput (cold) ... 35ATorque for the ground terminal nut ... 2.1 to 2.8 N m (19 to 25 lb in)(1) Torque for the pulley nut ... 102 7 N m (76 5 lb ft)(2) Torque for the output terminal nut ... 13.5 1.3 N m (10 1 lb ft)9G7567 Regulator. Under alternator cover. For use with the 7N9720 Alternator.
Voltage rating ... 28VPolarity ... Negative GroundVoltage setting range ... 26.7 to 28.3V5S9088 Alternator Group, 9G9538 Alternator 24V 50A
Load the battery with a carbon pile (4C4911 Battery Load Tester) to get the maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output voltage ... 27.5 1.0VOutput (cold) ... 63ATorque for the ground terminal nut ... 2.1 to 2.8 N m (19 to 25 lb in)(1) Torque for the pulley nut ... 95 to 110 N m (70 to 80 lb ft)(2) Torque for the output terminal nut ... 12 to 15 N m (9 to 11 lb ft)9G7567 Regulator. Under alternator cover. For use with the 9G9538 Alternator.
Voltage rating ... 28VPolarity ... Negative GroundVoltage setting range ... 26.7 to 28.3V6N9294 Alternator Group, 9G4574 Alternator 24V 35A
Load the battery with a carbon pile (4C4911 Battery Load Tester) to get the maximum alternator output.Polarity ... Negative GroundRotation ... Either DirectionSpeed for testing (rpm) ... 5000Output voltage ... 27.5 1.0VOutput (cold) ... 35A(1) Torque for the pulley nut ... 95 to 110 N m (70 to 80 lb ft)(2) Torque for the output terminal nut ... 22 to 37 N m (16 to 27 lb ft)(3) Torque for the ground terminal nut ... 3.4 to 5.4 N m