101603-2200 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016032200 220008990b


101603-2200 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-2200 1016032200
HINO 220008990B 220008990b

Cross reference number

ZEXEL 101603-2200 1016032200
HINO 220008990B 220008990b


Zexel num
Bosch num
Firm num
Name
101603-2200 
101603-2201 
 
220008990B  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

Test data 101603-2200
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=K30
----------

Speed control lever angle

Test data 101603-2200
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=46mm
----------
a=6deg+-5deg b=39deg+-3deg

Stop lever angle

Test data 101603-2200
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=38mm
----------
a=0deg+-5deg b=40deg+-5deg

0000001501 AIR CYLINDER

Test data 101603-2200
(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.
----------
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)
----------

Timing setting

Test data 101603-2200
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




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