101602-2210 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016022210 220202630a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-2210 1016022210

HINO 220202630A 220202630a

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Service parts 101602-2210 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-1730

3. GOVERNOR 105400-2360

4. SUPPLY PUMP 105210-4351

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

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

13. NOZZLE-HOLDER 105031-4341

14. NOZZLE

105015-3850

15. NOZZLE SET

Include in #1:

101602-2210 as INJECTION-PUMP ASSEMBLY

106672-9843 as _

Cross reference number

ZEXEL 101602-2210 1016022210

HINO 220202630A 220202630a

Zexel num

Bosch num

Firm num

Name

101602-2210

220202630A HINO

INJECTION-PUMP ASSEMBLY
EL100 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8140

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 131424-4220

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 4.9 4.85 4.95

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 7.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 76.9 74.9 78.9

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_02

Adjusting point B

Rack position 8.2

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 84.2 82.6 85.8

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Injection quantity adjustment_03

Adjusting point -

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 rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)RACK LIMIT: RAL (3)Idle sub spring setting: L1.
----------
K=18 RAL=14+0.2mm L1=4.5+-0.2mm
----------

Speed control lever angle

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

----------
a=3deg+-5deg b=20deg+-5deg

Stop lever angle

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

----------
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=(50deg)

Information:

Introduction
Do not perform any procedure in this Special Instruction until you read this information and you understand this information.Affected Engines
This Special Instruction provides the proper instructions on accessing the timing hole for high pressure fuel pumps on C7 Engines. The procedure is for the C7 Engines that are in General Motors and Blue Bird chassis. The timing hole may need to be accessed after the high pressure fuel injection pump is replaced in order to time the new high pressure pump.Disassembly Procedure
Illustration 1 g01458243
(1) Clean Gas Induction (CGI) Cooler (2) Aftertreatment Regeneration Device (ARD) Housing Bracket (3) Timing Hole Plug (4) Aftertreatment Regeneration Device (ARD) Housing
Illustration 2 g01458244
(5) Mounting bolts for the bracket for the ARD housing
Remove the two mounting bolts (5) from the bracket for the housing for the ARD. Use a 18 millimeter socket in order to loosen the mounting bolts. Make sure that the socket can flex. Also use a 12 inch socket extension in order to loosen the mounting bolts. After the bolts have been broken loose the bolts must be turned by hand in order to finish removing the bolts.
Illustration 3 g01458245
(6) Exhaust clamp for the ARD
Loosen the exhaust clamp (6) for the ARD. Slide the exhaust clamp down the exhaust pipe. Do not remove the clamp completely. This may cause the clamp to become bent. This may cause the clamp to not fit properly.
Illustration 4 g01458247
(7) Timing hole for the high pressure fuel pump
Move the housing bracket for the ARD to the side. This will provide enough clearance in order to remove the plug from the timing hole.The timing hole can be used to check the timing for the fuel injection pump. If the fuel injection pump needs to be timed properly then refer to Disassembly and Assembly, RENR9707, "Fuel Injection Pump - Install" for the proper installation procedure to ensure the the fuel injection pump will be timed properly.Assembly Procedure
Illustration 5 g01458476
(3) Timing hole plug
Reinstall the timing hole plug (3) back into the timing hole.
Illustration 6 g01458245
(6) Exhaust clamp for the ARD
Reinstall the exhaust clamp (6) for the ARD.
Illustration 7 g01458244
(5) Mounting bolts for the housing bracket for the ARD
Move the bracket for the ARD into the original position. Reinstall the mounting bolts (5) for the mounting bracket for the ARD.