101603-2420 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032420 220205030a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101603-2420 1016032420

HINO 220205030A 220205030a

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Buy INJECTION-PUMP ASSEMBLY 101603-2420 zexel genuine, new aftermarket engine parts with delivery

Service parts 101603-2420 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-5430

3. GOVERNOR 105401-0940

4. SUPPLY PUMP 105210-4351

5. AUTOM. ADVANCE MECHANIS 105672-0470

6. COUPLING PLATE 105662-1160

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105160-4270

11. Nozzle and Holder 23600-2820A

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

13. NOZZLE-HOLDER 105030-4440

14. NOZZLE 105025-0570

15. NOZZLE SET

Include in #1:

101603-2420 as INJECTION-PUMP ASSEMBLY

Include in #2:

104748-1662 as _

Cross reference number

ZEXEL 101603-2420 1016032420

HINO 220205030A 220205030a

Zexel num

Bosch num

Firm num

Name

101603-2420
101603-2421

220205030A 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 160.5 144 177

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 10.1

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 119 117.5 120.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Boost pressure kPa 28.7 28.7

Boost pressure mmHg 215 215

Injection quantity adjustment_02

Adjusting point C

Rack position 6.4+-0.5

Pump speed r/min 410 410 410

Average injection quantity mm3/st. 9 8 10

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 135 135 145

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Rack limit *

Boost compensator adjustment

Pump speed r/min 800 800 800

Rack position R1-1

Boost pressure kPa 8 8 8

Boost pressure mmHg 60 60 60

Boost compensator adjustment_02

Pump speed r/min 800 800 800

Rack position R1(10.1)

Boost pressure kPa 18 14 22

Boost pressure mmHg 135 105 165

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.3

Timer adjustment_03

Pump speed r/min 1050

Advance angle deg. 1.5 1.2 1.8

Remarks
Finish

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)Main spring setting (6)Boost compensator stroke: BCL
----------
K=12 BCL=1+-0.1mm
----------

Speed control lever angle

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

----------
a=8deg+-5deg b=20deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Pump speed aa and rack position bb (to be sealed at delivery) (2)Normal
----------
aa=0r/min bb=1-0.5mm
----------
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:

3. Install dowel (5) in governor shaft (6). Install the governor shaft in the carrier as shown. 4. Put the carrier in position on the camshaft. Install the bolts that hold the carrier in place.
Replace shield (7) with a new part any time it is removed.
5. Install shield (7) on the carrier, and use Tool (A) to push the shield against its seat. Use a hammer and punch to stake the metal in two places on the side of the shield 180° 5° apart next to the holes in the shield. 6. Install one race (9), bearing (10), the other race (9), and use Tool (B) to install the ring on riser (8) as shown. 7. Install riser (8) and the spring (overfueling spring) on the governor shaft as shown. 8. Assemble the dashpot as follows:a. Install spring (12) on seat (11). Install seat (13) in spring (12).b. Put spool (14) and ring (15) in position on seat (13). Use Tool (B) to install snap ring (16) to hold them in place. 9. Install dashpot assembly (17) on the governor shaft as shown. 10. Install ring (21) in the lower groove in the governor shaft. Install one sleeve (20), spring (19), the other sleeve (20) and bearing (18) on the governor shaft as shown. Spring (19) is used to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing.11. Use Tool (C) to hold spring (19) under compression. Install ring (22) in the groove in the governor shaft. Remove Tool (C). 12. Put lever (27) in position on governor servo (23). Install pin (24) to hold the lever in place. Use a hammer and chisel to stake the metal four places 90° apart on the outside surface on both legs of the governor servo to hold pin (24) in place.13. Install the O-ring seal on sleeve (25). Install piston (26) and sleeve (25) in the governor servo as shown. 14. Install valve (28) in the governor servo as shown. 15. Install one lockring (32) in the groove near the center of valve (28). Put sleeve (29), spring (broken link spring) (30) and seat (31) in position on valve (28). Install the other lockring (32) to hold the components in place. 16. Put the governor servo in position on the fuel injection pump housing with piston (26) engaged over rack (33). Install the bolts that hold the governor servo in place. The 3306 Engine has two adjustment screws and lock nuts.17. Install torque rise adjustment screw (36) in collar (34) as shown. Install locknut (35) on the screw. 18. Install bolt (38) in block (40) as shown. Install spring (37) on bolt (38) as shown. Put collar (34) in position on bolt (38) with the hole in the collar