101603-2062 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032062 220204342a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-2062 1016032062

HINO 220204342A 220204342a

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Buy INJECTION-PUMP ASSEMBLY 101603-2062 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2062 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5310

3. GOVERNOR 105401-0631

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS 105614-3660

6. COUPLING PLATE 105662-1280

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6750

11. Nozzle and Holder 23600-2490A

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

13. NOZZLE-HOLDER 105030-4440

14. NOZZLE 105015-9220

15. NOZZLE SET

Include in #1:

101603-2062 as INJECTION-PUMP ASSEMBLY

101603-8472 as _

Cross reference number

ZEXEL 101603-2062 1016032062

HINO 220204342A 220204342a

Zexel num

Bosch num

Firm num

Name

101603-2062
101603-2063

220204342A HINO

INJECTION-PUMP ASSEMBLY
H07C-T * K 14BF PE6AD 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 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 10.9

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 99 97.5 100.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 34.7 34.7

Boost pressure mmHg 260 260

Injection quantity adjustment_02

Adjusting point -

Rack position 6.3+-0.5

Pump speed r/min 495 495 495

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.

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 130 130 140

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 11.3

Boost pressure kPa 13.3 10.6 16

Boost pressure mmHg 100 80 120

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position 12

Boost pressure kPa 21.3 21.3 21.3

Boost pressure mmHg 160 160 160

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)RACK LIMIT (4)Set idle sub-spring (5)Boost compensator stroke (6)Rack difference between N = N1 and N = N2 (7)Main spring setting
----------
K=10 N1=1100r/min N2=500r/min
----------

Speed control lever angle

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

----------
a=5deg+-5deg b=23deg+-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:

(1) Torque for the terminal nuts ... 30 3 N m (22 2 lb ft)(2) Torque for the screws that hold the nose housing to the lever housing ... 20 3 N m (15 2 lb ft)Clearance between the pinion and housing (pinion clearance) ... 8.3 to 9.9 mm (.33 to .39 in)8C3651 24V
Rotation as seen from the drive end ... clockwiseNo load conditions: Speed (rpm) ... 7350 1050Current amps ... 60 to 75Voltage ... 23Used with solenoid ... 7T02584N3180 24V, 2P3926 24V
The two 10-32 screws on the underside of the solenoid are tightened to a torque of ... 2 to 3 N m (16 to 30 lb in)Rotation as seen from the drive end ... clockwiseNo load conditions: Speed (rpm) ... 6000 to 8250Current amps ... 155 15Voltage ... 23Used with solenoid ... 3T34213T2647 24V
The two 10-32 screws on the solenoid are tightened to a torque of ... 2.25 0.25 N m (20 2 lb in)The two 1/2-13 nuts on the solenoid are tightened to a torque of ... 31 4 N m (23 3 lb ft)Rotation as seen from the drive end ... clockwiseNo load conditions: Speed (rpm) ... 8130 2130Current amps ... 89 29Voltage ... 23Used with solenoid ... 7T88543T8946 24V
Rotation as seen from the drive end ... clockwiseNo load conditions: Speed (rpm) ... 6500 1000Current amps ... 107.5 12.5Voltage ... 20Used with solenoid ... 7T88549G4338 24V
Rotation as seen from the drive end ... clockwiseMinimum (no load) speed (rpm) ... 6500Current consumption (draw) at 20V (no load) ... 77A(1) Torque for the housing bolts ... 11 N m (8 lb ft)(2) Torque for the terminal nuts ... 27 to 34 N m (20 to 25 lb ft)(3) Clearance between the pinion and housing ... 0.51 to 1.27 mm (.020 to .050 in)Used with solenoid ... 3T86353T6305 24V
Rotation as seen from the drive end ... clockwiseMaximum (no load) speed (rpm) ... 5500Maximum current consumption (draw) (no load) ... 200A(1) Torque for the large terminal nuts ... 27 to 33 N m (20 to 24 lb ft) Torque for the small terminal nuts ... 4 to 5 N m (35 to 45 lb in)(2) Service limit of brushes ... 17.5 mm (.69 in)(3) Service limit of commutater diameter ... 48 mm (1.9 in)Pinion to ring gear clearance ... 1.5 to 5.5 mm (.06 to .22 in)Used with solenoid ... 9X03329X4447 24V
(1) Torque for terminal nuts: Small terminal nuts ... 2.25 .25 N m (20 2 lb ft)Large terminal nuts ... 30.5 3.5 N m (22.5 2.5 lb ft)No load conditions: Speed (rpm) ... 3300Current amps ... 80AVoltage ... 23.5Used with solenoid ... 3E0135