101602-2050 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016022050 220201360a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-2050 1016022050

HINO 220201360A 220201360a

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Service parts 101602-2050 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-1300

3. GOVERNOR 105400-1930

4. SUPPLY PUMP 105210-4350

5. AUTOM. ADVANCE MECHANIS

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:

101602-2050 as INJECTION-PUMP ASSEMBLY

Include in #2:

104274-5000 as _

Cross reference number

ZEXEL 101602-2050 1016022050

HINO 220201360A 220201360a

Zexel num

Bosch num

Firm num

Name

101602-2050
101602-2053

220201360A 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 A

Rack position 8

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 80.7 79.1 82.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 4.3+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 9.5 8 11

Max. variation between cylinders % 0 -15 15

Fixing the lever *

Injection quantity adjustment_03

Adjusting point C

Rack position 14+-0.5

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 166 156 176

Fixing the rack *

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT
----------
K=6
----------

Speed control lever angle

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

----------
a=4.5deg+-5deg b=27deg+-5deg

Stop lever angle

N:Pump normal S:Engine stop
----------

----------
a=27deg+-5deg b=53deg+-5deg

Timing setting

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

----------
a=(60deg)

Information:

Required Parts
Table 1
Required Parts List
Item Qty New Part Number Part Name Former Part Number(1)
1 1 525-3348 Plate As 461-5730
2 1 398-2993 Tank Filler Cap 398-3011
3 1 525-3357 Cover As 431-4872
4 4 9X-2038 Washer 5P-4115
5 4 8T-4138 Bolt -
6 1 246-2641 Padlock -
7 1 525-3351 (2) Guard As 461-5732
(1) The former part number listed is for reference only and may differ.
(2) For Heavy Duty(HD) rear guard assembly.Standard Rear Plate Assembly
Illustration 1 g06212425
(A) 447-5514 Film
(B) 430-3036 Film
(C) For english use 484-5902 Film and for international use 393-2614 FilmHeavy Duty Rear Guard Assembly
Illustration 2 g06212430Rework Procedure - Heavy Duty Rear Guard Assembly
Description: To adapt early heavy duty rear guard assembly (with DEF door design) for assembly with new standard rear plate assembly.Note: This rework will not provide the heavy duty shroud on the guard assembly (7) at the fill opening, that comes on the new heavy duty rear guard assembly from the factory as shown in the Illustration 2. Only the shroud on the new standard rear plate assembly (1) will be in place to protect that fill location as shown in the Illustration 2.
Illustration 3 g06213073
(D) door
(E) hinge
Remove the hinge (E) and door (D).
Illustration 4 g06212502
Cutout section with rounded corners
(F) 190 mm (7.5 inch)
(G) 40 mm (1.8 inch)
(H) 40 mm (1.8 inch)
(I) 95 mm (3.7 inch)
Illustration 5 g06212524
Cutout section with chamfered corners
(J) 55 mm (2.2 inch)
(K) 15 mm (0.6 inch)
(L) 80 mm (3.2 inch)
Cutout section from opening down by a clearance of (H) from original radius (G). The cutout should extend the entire width of opening. But corners can be significantly rounded as per dimensions shown in the Illustration 4 or chamfered as per dimensions shown in the Illustration 5. Either method is acceptable.Note: If DEF in the hydraulic tank is suspected, do not start the engine or operate the machine without first reviewing Special Instruction , M0064940 for procedure to address inadvertent adding of DEF to the machine hydraulic tank.