101603-2250 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032250 220009060a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-2250 1016032250

HINO 220009060A 220009060a

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Cross reference number

ZEXEL 101603-2250 1016032250

HINO 220009060A 220009060a

Zexel num

Bosch num

Firm num

Name

101603-2250
101603-2251

220009060A HINO

INJECTION-PUMP ASSEMBLY
H07D * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 18

Opening pressure kgf/cm2 184

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)
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 3.97 4.03

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 11.3

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 93 91 95

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+-0.5

Pump speed r/min 265 265 265

Each cylinder's injection qty mm3/st. 15 14 16

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.3)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 93 92 94

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.8

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 96 92 100

Fixing the lever *

Injection quantity adjustment_05

Adjusting point D

Rack position R1-0.8

Pump speed r/min 580 580 580

Average injection quantity mm3/st. 74.5 70.5 78.5

Fixing the lever *

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 140 150

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 1100+50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1450-50

Advance angle deg. 3.5 3.2 3.8

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=L26
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Speed control lever angle

F:Full speed I:Idle (1)Use the pin at R = aa (2)Stopper bolt set position 'H'
----------
aa=57mm
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a=38deg+-3deg b=44deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg

0000001501 TAMPER PROOF

1. Method for setting tamperproof proofing (1)Perform after governor adjustment (torque cam phase adjustment). (2)Increase the full rack position to Ra using the load lever. (3)Push in screw (A) to Rb. (4)Temporarily caulk using the tip of a screwdriver (5)Confirm that the rack at that time is at Rb . (6)Lock using setscrew (B). (Tightening torque = T) (7)Pressfit (C) after applying adhesive. (8)Readjust the full rack using the load lever.
----------
Ra=R1+0.45+-0.1mm Rb=R1+0.45+-0.1mm
----------
T=3.4~4.9N-m(0.35~0.5Kgf-m)

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) Balancer unit idler gear: Inside diameter of gear bore ... 47.635 to 47.650 mm (1.8754 to 1.8760 in)Outside diameter of gear bearing ... 47.63 mm (1.875 in)Inside diameter of gear bearing ... 38.1 mm (1.50 in)Outside diameter of idler gear hub ... 38.090 to 38.100 mm (1.4996 to 1.5000 in)Idler gear end play ... 0.08 to 0.23 mm (.003 to .009 in)Torque for idler gear bolt ... 75 N m (55 lb ft)(2) Idler gear thrust washer: Thrust washer thickness ... 4.14 to 4.29 mm (.163 to .169 in)Outside diameter of thrust washer ... 59.00 mm (2.323 in)Inside diameter of thrust washer ... 19.99 mm (0.787 in)
Be sure thread lock does not get on gear shaft drive needle bearing or it can cause the needle bearing to fail.
(3) Put 9S3263 Thread Lock on balance weight drive gear splines and threads for nut (3). Torque for nut ... 85 N m (65 lb ft)Diameter of balance weight drive gear splines ... 16.51 to 16.54 mm (.650 to .651 in)
If the oil transfer cover plate arrow points to the wrong side of the engine, the engine will seize due to the lack of lubrication.
(4) Torque for end cover bolts ... 55 N m (40 lb ft)(5) Install oil transfer cover plate with arrow pointing to side of engine that oil filter is on. Torque for cover plate bolts ... 30 N m (24 lb ft)(6) Gear shaft drive: Diameter of drive shaft at front bearing ... 28.55 to 28.58 mm (1.124 to 1.125 in)Diameter of drive shaft at rear bearing ... 23.77 to 23.80 mm (.936 to .937 in)Diameter of oil pump drive splines ... 28.55 to 28.58 mm (1.124 to 1.125 in)Diameter of front bearing bore ... 34.90 to 34.93 mm (1.374 to 1.375 in)Outside diameter of front bearing ... 34.920 mm (1.3748 in)Inside diameter of front bearing ... 28.58 mm (1.125 in)Diameter of rear bearing bore ... 45.72 to 45.85 mm (1.800 to 1.805 in)Outside diameter of rear bearing ... 30.00 mm (1.181 in)Inside diameter of rear bearing ... 23.80 mm (.937 in)End play of drive shaft ... 0.170 to 0.348 mm (.0067 to .0137 in)(7) Drive shaft front bearing dimension below front face of frame ... 2.49 to 3.00 mm (.098 to .118 in)(8) Length of drive shaft between rear bearing and front face of shaft ... 130.20 to 131.17 mm (5.126 to 5.164 in)(9) Drive shaft rear bearing dimension below machined surface ... 0.201 to 2.997 mm (.0079 to .1180 in) (10) Balance weights: Diameter of balance frame and end bushing bores ... 42.06 to 42.09 mm (1.656 to 1.657 in)Outside diameter of balance frame and end frame bushings ... 42.2 mm (1.66 in)Inside diameter of balance frame and end frame bushings ... 38.13 to 38.18 mm (1.501 to 1.503 in)Shaft diameter of balance weights ... 38.05 to 38.07 mm (1.498 to 1.499 in)Clearance between balance weight shafts and bushings ... 0.064