101603-2190 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032190 220008952a

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

ZEXEL 101603-2190 1016032190

HINO 220008952A 220008952a

Cross reference number

ZEXEL 101603-2190 1016032190

HINO 220008952A 220008952a

Zexel num

Bosch num

Firm num

Name

101603-2190
101603-2191

220008952A 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 12.5

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 400 400 400

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(12.5)

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
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T1=K31
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
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aa=38mm
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a=29deg+-5deg b=(38deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
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aa=38mm
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a=0deg+-5deg b=40deg+-5deg

0000001501 AIR CYLINDER

(A): Speed lever (B): Set bolt (C): air cylinder (D): nut (E): fix 1. Air cylinder adjustment procedure (1)With the speed lever in the idling position, temporarily set the clearance between speed lever (A) and set bolt (B) at approximately L1. (2)Set the speed to N1 and supply positive pressure P1 to the air cylinder (C). (3)Gradually push set bolt (B) out (approximately L2) and tighten nut (D) where the speed is N2 and the rack position is Ra. (4)Apply positive pressure P1 several times. (5)Confirm that the lever returns to the idle position at positive pressure P2. (6)Also, confirm that the rack position is Rb at air pressure P1.
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L1=5mm L2=5mm Ra=9.4+-0.1mm Rb=9.4+-0.1mm N1=350r/min N2=350r/min P1=392+98kPa(4+1kgf/cm2) P2=0kPa(0kgf/cm2)
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