101601-2410 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016012410 220002001a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-2410 1016012410

HINO 220002001A 220002001a

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Service parts 101601-2410 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-1200

3. GOVERNOR

4. SUPPLY PUMP 105210-4350

5. AUTOM. ADVANCE MECHANIS 105634-0070

6. COUPLING PLATE 105662-0550

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4303

11. Nozzle and Holder 23600-1171

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105031-4341

14. NOZZLE

105015-3850

15. NOZZLE SET

Include in #1:

101601-2410 as INJECTION-PUMP ASSEMBLY

101695-3850 as _

Cross reference number

ZEXEL 101601-2410 1016012410

HINO 220002001A 220002001a

Zexel num

Bosch num

Firm num

Name

101601-2410
101601-2412

220002001A HINO

INJECTION-PUMP ASSEMBLY
EL100 *

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 134424-0620

Overflow valve opening pressure kPa 162 147 177

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 4.85 4.8 4.9

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point B

Rack position 9

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 86.7 85.1 88.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 9.7

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 100.7 98.1 103.3

Max. variation between cylinders % 0 -3 3

Fixing the lever *

Injection quantity adjustment_03

Adjusting point D

Rack position 4.9+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 6 4.5 7.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_04

Adjusting point E

Rack position 11.4+-0. 5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 78 78 98

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1150+-50

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1300

Advance angle deg. 1.9 1.4 2.4

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 3.5 3 4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Excess fuel setting for starting: SXL
----------
DL=4-0.5mm SXL=9.7+0.2mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=11deg+-5deg

0000000901

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

----------
a=18deg+-5deg b=27deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=21deg+-5deg b=69deg+-5deg

0000001501 MICRO SWITCH

Switch adjustment Adjust the bolt so that the lower lever position is obtained when the switch is turned ON. (1)Speed N1 (2)Rack position Ra
----------
N1=350+25r/min Ra=4.9mm
----------

Information:

1. Remove the tube (1) from the turbocharger to the aftercooler.2. Remove the valve cover (2) from the engine.3. Turn the crankshaft until the No. 1 piston is at top center on the compression stroke. See LOCATING TOP CENTER COMPRESSION POSITION FOR THE NO. 1 PISTON in TESTING AND ADJUSTING. 4. Remove the camshaft driveshaft cover at the top of the flywheel housing. Install a 3/8" - 16 NC forged eyebolt in the driveshaft (3) and remove the driveshaft. On engines with a BrakeSaver, remove two plugs (4) from the flywheel housing.5. Disconnect glow plug wiring harness from the glow plugs and valve cover base. Remove the inner fuel injection lines. Put plugs or caps on all fuel lines and openings. 6. Remove the fifteen other bolts and locks (seven each side and one in rear). Remove two of the glow plug wiring harness mounting bolts and install two 3/8" - 16 NC forged eyebolts. Pull the camshafts (5) off dowels. Fasten a hoist and remove the camshafts (5). Weight of the camshafts is 100 lb. (45 kg).Install Camshafts
1. Adjust all of the camshaft followers to give maximum clearance. 2. Put the camshaft phasing gear timing marks (1) together and in a horizontal plane. 3. Install two 3/8" - 16 forged eyebolts. Fasten a hoist and install the camshafts (2) on the engine. Install the camshaft retaining bolts and locks.
Never install the camshafts if the No. 1 piston is not at top center on the compression stroke. Damage to the engine can be the result if No. 1 piston is not in correct position.
4. Remove the eyebolts and install the glow plug wiring harness mounting bolts.5. Install the inner fuel injection lines. Tighten retaining nuts to 30 5 lb.ft. (40.7 6.8 N m).6. Connect the glow plug wiring to the plugs and to the valve cover base.7. Install the camshaft driveshaft with the alignment (blind) spline on top. Install driveshaft cover.8. Remove the timing bolt from the flywheel. Install the plug in the flywheel housing and timing bolt in the cover.9. Adjust the inlet valve clearance to .018 in. (0.46 mm) and the exhaust valve clearance to .030 in. (0.76 mm). 10. Install the valve cover (3) and the tube (4) from the turbocharger to the aftercooler.