Information injection-pump assembly
ZEXEL
101603-2131
1016032131
HINO
220008380D
220008380d
Rating:
Cross reference number
ZEXEL
101603-2131
1016032131
HINO
220008380D
220008380d
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
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
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
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
Governor side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
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
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.
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.
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
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
----------
----------
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=(46deg)+-3deg
----------
aa=41mm
----------
a=6deg+-5deg b=(46deg)+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
(2)Set the stopper screw so that speed = bb and the rack position = cc and confirm non-injection.
(3)After setting the stopper bolt, confirm non-injection at speed dd. Rack position = non-injection rack position (actual measurement)
----------
aa=38mm bb=1610r/min cc=6.5-0.5mm dd=275r/min
----------
a=0deg+-5deg b=(26deg)+-5deg
----------
aa=38mm 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)
----------
----------
a=(20deg)
Information:
(1) 7S7144 Spring for valves (new): Length under test force ... 44.86 mm (1.766 in)Test force ... 257 25 N (57.7 4.5 lb)Length of spring at valve open position ... 32.28 mm (1.271 in)Load at minimum operating length ... 708 35 N (160 8 lb)Free length after test ... 52.07 mm (2.05 in)Outside diameter ... 35.21 mm (1.386 in)Spring must not be bent more than ... 1.82 mm (.072 in)(2) Height to top of valve guide ... 22.23 0.25 mm (.875 .010 in)(3) Diameter of valve stem (new) ... 9.441 0.008 mm (.3717 .0003 in) Use again minimum diameter ... 9.408 mm (.3704 in)Bore in valve guide with guide installed in the head.Minimum permissible (new) ... 9.456 mm (.3723 in)Maximum permissible (worn) ... 9.581 mm (.3772 in)(4) Valve lip thickness: 6N9916 Exhaust Valve Use again minimum ... 2.69 mm (.106 in)2W2620 Intake Valve Use again minimum ... 2.69 mm (.106 in)6N9915 Intake Valve Use again minimum ... 2.44 mm (.096 in)(5) Diameter of valve head: Exhaust valve ... 48.16 0.13 mm (1.896 .005 in)Intake valve ... 51.31 0.13 mm (2.020 .005 in)(6) Angle of valve face ... 29 1/4 1/4° (7) Depth of bore in head for valve seat insert ... 12.28 0.13 mm (.483 .005 in)(8) Diameter of valve seat insert for exhaust valve ... 50.889 0.013 mm (2.0035 .0005 in) Bore in head for valve seat insert for exhaust valve ... 50.813 0.030 mm (2.0005 .0012 in)Diameter of valve seat insert for intake valve ... 52.032 0.013 mm (2.0485 .0005 in)Bore in head for valve seat insert for intake valve ... 51.956 0.030 mm (2.0455 .0012 in)(9) Angle of face of valve seat insert ... 30 1°(10) Maximum permissible width of valve seat (intake and exhaust) ... 1.93 mm (.076 in) Minimum permissible width of valve seat (intake and exhaust) ... 1.14 mm (.045 in)(11) Dimension from top of closed valve to face of head: Minimum permissible dimension for 6N9916 Exhaust Valve ... 0.66 mm (.026 in)Minimum permissible dimension for 6N9915 or 2W2620 Intake Valve ... 0.15 mm (.006 in)(12) Outside diameter of the face of the valve seat insert: Exhaust seat ... 46.02 mm (1.812 in)Maximum permissible, exhaust seat ... 47.29 mm (1.862 in)Intake seat ... 49.28 mm (1.940 in)Maximum permissible, intake seat ... 50.55 mm (1.990 in)(13) Angle to grind seat face of the insert to get a reduction of maximum seat diameter ... 15°