101603-2300 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032300 220009240a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-2300 1016032300

HINO 220009240A 220009240a

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Service parts 101603-2300 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6171

3. GOVERNOR 105932-1880

4. SUPPLY PUMP 105210-6060

5. AUTOM. ADVANCE MECHANIS 105680-5010

6. COUPLING PLATE 105662-1460

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7705

11. Nozzle and Holder 23600-2663C

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}

13. NOZZLE-HOLDER 105030-3601

14. NOZZLE

15. NOZZLE SET 105019-0314

Include in #1:

101603-2300 as INJECTION-PUMP ASSEMBLY

101603-7522 as _

Cross reference number

ZEXEL 101603-2300 1016032300

HINO 220009240A 220009240a

Zexel num

Bosch num

Firm num

Name

101603-2300
101603-2301

220009240A HINO

INJECTION-PUMP ASSEMBLY
J-2 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

Bosch type code 1 688 901 101

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 20.7

Opening pressure kgf/cm2 211

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.8 3.77 3.83

Beginning of injection position
Governor 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 12.4

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 104.5 102.5 106.5

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 9.5+-0.5

Pump speed r/min 375 375 375

Each cylinder's injection qty mm3/st. 13 12 14

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(12.4)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 104.5 103.5 105.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 109.5 105.5 113.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.55

Pump speed r/min 1160 1160 1160

Average injection quantity mm3/st. 109 105 113

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 950--

Advance angle deg. 0 0 0

Load 1/5

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.3

Load 1/5

Timer adjustment_03

Pump speed r/min -

Advance angle deg. 1.25 0.95 1.55

Load 5/5

Remarks
Measure the actual speed.

Timer adjustment_04

Pump speed r/min (1190++)

Advance angle deg. 1.25 0.95 1.55

Load 2/5

Remarks
Measure the actual speed.

Timer adjustment_05

Pump speed r/min 1255-50

Advance angle deg. 1.25 0.95 1.55

Load 5/5

Timer adjustment_06

Pump speed r/min 1420-50

Advance angle deg. 5.5 5.2 5.8

Load 5/5

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=K67
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=41mm
----------
a=6deg+-5deg b=(45.5deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper bolt at speed = bb and rack position = cc (non-injection rack position). Confirm non-injection. (3)After setting the stopper bolt, confirm non-injection at speed dd. Rack position = non-injection rack position (actual measurement)
----------
aa=50mm bb=1610r/min cc=6.5-0.5mm dd=275r/min
----------
a=0deg+-5deg b=(26deg)+-5deg

Timing setting

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

----------
a=(20deg)

Information:

Solenoid Valve Replacement
Make reference to the at the beginning of the Testing And Adjusting section.
This procedure assumes that the ether cylinder mounted on the failed solenoid valve may still contain ether and is usable. If the ether cylinder is empty and needs replacement, complete this procedure and then follow the normal cylinder replacement procedure. See Ether Cylinder Replacement.
Solenoid Valve Assembly The solenoid valve itself is not serviceable. The complete solenoid valve assembly must be replaced. This includes the mounting bracket.1. Turn the disconnect switch to the OFF position. 2. Remove the ether cylinder from failed solenoid valve (1).3. Disconnect ether line (2) from the outlet of failed solenoid valve (1).4. Disconnect (unplug) solenoid valve harness connector (3). 5. Remove the reset switch bracket from the solenoid valve by removing two bolts (4). Leave the reset switch and wires intact on the bracket.6. Remove the solenoid valve assembly, which includes the mounting bracket, from the vehicle by removing two bolts (5).
Orifice Fitting And Filter7. Prepare the new solenoid valve for installation by installing a new orifice fitting and filter.
The orifice fitting has left-hand threads.
8. Attach the new solenoid valve and reset switch bracket to the vehicle. Tighten top two bolts (5) and leave lower two bolts (4) loose.
Gasket Filter9. Install a new gasket filter into the inlet of the solenoid valve.10. Install the same ether cylinder. See within Ether Cylinder Replacement. Hand tighten the ether cylinder to the solenoid valve. 11. Adjust the reset switch bracket such that reset switch button (6) depresses as much as possible while contacting the ether cylinder. Tighten lower two bolts (4) which fasten the reset switch bracket and solenoid valve to the vehicle. The reset switch must be adjusted correctly in order for the ether injection system to operate properly. The function of the reset switch is: to be OPEN (depressed switch button) when an ether cylinder is installed, and to be CLOSED (extended switch button) when the ether cylinder is removed. Ether injection is disabled when an ether cylinder is removed (reset switch closed).12. Verify that the reset switch is OPEN by continuity checking between the pin and socket in harness plug (7) of the reset switch. There should be no continuity.13. Reconnect the harnesses to the solenoid valve and the reset switch. Turn the disconnect switch to the ON position.Ether Cylinder Removal
Non-Empty Cylinders
During maintenance or servicing, the ether cylinders may need to be removed when they are not empty (for example, the cylinders may have to be removed to gain access to some other item requiring service). Under these conditions, it is desirable to remove and reinstall the ether cylinders without disturbing the "ether cylinder timers" within the ether injection control. This procedure allows the same ether cylinder to be reinstalled after it has been removed. Normal ether cylinder replacement is performed when the ether cylinder is empty. Normal removal of an empty ether cylinder resets the "ether cylinder timers" within the ether injection control. See Ether Cylinder Replacement. Failure to