101602-2570 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016022570 220203750a

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101602-2570 1016022570

HINO 220203750A 220203750a

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Buy INJECTION-PUMP ASSEMBLY 101602-2570 zexel genuine, new aftermarket engine parts with delivery

Service parts 101602-2570 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-9640

3. GOVERNOR 105401-0460

4. SUPPLY PUMP 105220-5590

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156637-9520

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105110-4380

11. Nozzle and Holder 23600-1780

12. Open Pre:MPa(Kqf/cm2) 21.6{220}

13. NOZZLE-HOLDER 105041-5090

14. NOZZLE 105015-7080

15. NOZZLE SET

Include in #1:

101602-2570 as INJECTION-PUMP ASSEMBLY

Include in #2:

104258-3000 as _

Cross reference number

ZEXEL 101602-2570 1016022570

HINO 220203750A 220203750a

Zexel num

Bosch num

Firm num

Name

101602-2570
101601-5870

220203750A HINO

INJECTION-PUMP ASSEMBLY
W06D-TI * 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 131424-6420

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 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 4.4 4.35 4.45

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 12.2

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 146 144 148

Max. variation between cylinders % 0 -3 3

Basic *

Fixing the lever *

Boost pressure kPa 60 60

Boost pressure mmHg 450 450

Injection quantity adjustment_02

Adjusting point B

Rack position 7.4+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 10.5 9 12

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R1-2

Boost pressure kPa 10.7 8 13.4

Boost pressure mmHg 80 60 100

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R1(12.2)

Boost pressure kPa 46.7 40 53.4

Boost pressure mmHg 350 300 400

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Set idle sub-spring (3)Main spring setting (4)Boost compensator stroke (at N = N1)
----------
K=6 N1=600r/min
----------

Speed control lever angle

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

----------
a=8deg+-5deg b=28deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Speed = aa, rack position = bb (sealed at shipping)
----------
aa=0r/min bb=1-0.2mm
----------
a=21deg+-5deg b=(55deg)

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(70deg)

Information:

Installing the Red LED Lamp (Regeneration Disable Lamp)
Illustration 1 g02402796
242-3282 Led Lamp As Use 155-2269 Connector Plug As as a mating connector. 155-2269 Connector Plug As is not included in the kit. Also, 102-8802 Receptacle Kit contains 3E-3364 Receptacle and 3E-3365 Receptacle Lock Wedge .
Insert the red (power) wire from the 242-3282 LED Lamp As into terminal 1 of 3E-3364 Receptacle .
Insert the black (ground) wire from the LED lamp into terminal 2 of the receptacle.
Insert 3E-3365 Receptacle Lock Wedge is the receptacle.
Connect terminal 1 of the receptacle to terminal 13 of 160-7689 Connector Plug As .
Connect terminal 2 of the receptacle to the ground/return (-).Installing the Illuminated Plug (Regeneration Lamp)
Illustration 2 g02402326
332-1064 Illuminated Plug The terminal designations can be found on the sides of 332-1064 Illuminated Plug and 205-5471 Connector .
Connect terminal 1A of the connector to the battery power (+).
Connect terminal 2A of the connector to the battery power (+).
Connect terminal 1B of the connector to terminal 30 of the plug.
Connect terminal 2B of the connector to terminal 31 of the plug.
Crimp the 112-9611 Blade Terminal onto the wires necessary to create the connections described in the previous steps.
Insert the blade terminals into the appropriate terminal locations of the connector.
Connect the plug to the connector. The plug and the connector are mating connectors.Installing the Hydraulic Lockout Rocker Switch (High Speed Regeneration Rocker Switch)
Illustration 3 g02366857
284-3623 Rocker Switch The terminal designations can be found on the sides of the 223-4778 Connector Plug As .
Insert 288-7146 Wire As into terminals 2,3,5, and 9 of the plug.
Splice the unoccupied ends of two 288-7146 Wire As together. Insert the spliced wire to provide a connection for terminal 6 to terminal 7 of 223-4778 Connector Plug As .
Connect terminal 2 of 223-4778 Connector Plug As to terminal 18 of 160-7689 Connector Plug As .
Connect