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


101603-2300 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

ZEXEL 101603-2300 1016032300
HINO 220009240A 220009240a

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

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

Test data 101603-2300
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

Test data 101603-2300
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

Test data 101603-2300
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

Test data 101603-2300
(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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