101601-5723 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015723 220006982a


 

Information injection-pump assembly

ZEXEL 101601-5723 1016015723
HINO 220006982A 220006982a
101601-5723 INJECTION-PUMP ASSEMBLY
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Service parts 101601-5723 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-5210
3. GOVERNOR 105921-4313
4. SUPPLY PUMP 105210-5240
5. AUTOM. ADVANCE MECHANIS 105672-0120
6. COUPLING PLATE 105662-1160
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-6280
11. Nozzle and Holder 23600-2133
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105030-4300
14. NOZZLE 105015-8590
15. NOZZLE SET

Include in #1:

101601-5723 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101601-5723 1016015723
HINO 220006982A 220006982a


Zexel num
Bosch num
Firm num
Name
101601-5723 
101601-5724 
 
220006982A  HINO
INJECTION-PUMP ASSEMBLY
H07D-A * K 14BF PE6AD PE

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   131424-8320
Overflow valve opening pressure kPa   108 88 128
Overflow valve opening pressure kgf/cm2   1.1 0.9 1.3
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   3.8 3.77 3.83
Beginning of injection position
Drive side
  NO.1
Difference between angles 1
Cal 1-4
deg.   60 59.75 60.25
Difference between angles 2
Cyl.1-2
deg.   120 119.75 120.25
Difference between angles 3
Cal 1-6
deg.   180 179.75 180.25
Difference between angles 4
Cal 1-3
deg.   240 239.75 240.25
Difference between angles 5
Cal 1-5
deg.   300 299.75 300.25
Injection quantity adjustment
Adjusting point   -
Rack position   11.5
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   76.1 74.5 77.7
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   H
Rack position   9+-0.5
Pump speed r/min   250 250 250
Each cylinder's injection qty mm3/st.   15 14 16
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(11.5)
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   76.1 75.1 77.1
Basic   *
Fixing the lever   *
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1+0.45
Pump speed r/min   1450 1450 1450
Average injection quantity mm3/st.   86.8 82.8 90.8
Fixing the lever   *
Injection quantity adjustment_05
Adjusting point   C
Rack position   R1-0.25
Pump speed r/min   580 580 580
Average injection quantity mm3/st.   62.8 58.8 66.8
Fixing the lever   *
Injection quantity adjustment_06
Adjusting point   D
Rack position   R1+0.45
Pump speed r/min   1150 1150 1150
Average injection quantity mm3/st.   85.4 81.4 89.4
Fixing the lever   *
Injection quantity adjustment_07
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   925--
Advance angle deg.   0 0 0
Load   1/4
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   875
Advance angle deg.   0.3
Load   1/4
Timer adjustment_03
Pump speed r/min   (920--)
Advance angle deg.   1 0.7 1.3
Load   4/4
Timer adjustment_04
Pump speed r/min   1175+50
Advance angle deg.   1 0.7 1.3
Load   3/4
Timer adjustment_05
Pump speed r/min   1400+50
Advance angle deg.   5.5 5.2 5.8
Load   4/4
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101601-5723
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=H16
----------

Speed control lever angle

Test data 101601-5723
F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=(40deg)+-3deg b=44deg+-5deg

Stop lever angle

Test data 101601-5723
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=35mm
----------
a=14.5deg+-5deg b=40deg+-5deg

Timing setting

Test data 101601-5723
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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




Information:

The engine is turbocharged and air-to-air aftercooled (ATAAC) with direct fuel injection.The 3176 is an electronically controlled, mechanically actuated unit injector diesel engine. Timing advance is achieved by precise control of injector firing. Engine speed is controlled by adjusting the firing duration. A pulse wheel provides information to the fuel cooled ECM (Electronic Control Module) for detection of cylinder position and engine speed.The 3176 electronic engine control system was designed to provide electronic governing, automatic air fuel ratio control, torque rise shaping, injection timing control and system diagnostics. Additional benefits such as cruise control, vehicle speed limiting, low and high gears engine speed limiting (progressive shift engine speed control), PTO governor, data link and multi-torque ratings provide for additional engine fuel economy, driver comfort and serviceability.The fuel system is a mechanically actuated, electronically controlled unit injector combining the pumping, electronic fuel metering and injecting elements in a single unit to produce higher injection pressures (22,000 psi [151 600 kPa]). High injection pressures help to reduce fuel consumption and particulate emissions.The use of this type of unit injector provides total electronic control of injection timing. The injection timing is varied as a function of engine operating conditions. This optimizes the engine's performance for starting, emissions, noise, fuel consumption and driveability.A full range electronic governor is utilized and controls the fuel injection output to maintain the engine speed desired by the 3176 system. The governor functions like the Caterpillar mechanical governor in the mid-range, but includes additional features. These include programmable isochronous low idle and 20 rpm governor overrun.The 3176 has built-in diagnostics to assure that all components are functioning and operating properly. In the event of a system component deviation from programmed limits, the operator will be alerted to the condition by a dashboard mounted "Check Engine" light.A Caterpillar service tool may be used to read the numerical code of the faulty component. Intermittent faults are logged and stored in the system memory. Refer to Engine Diagnostics section of this publication for alternative methods.The cooling system consists of a gear driven pump, with one thermostat which regulates the engine coolant temperature, a plate type oil cooler and a radiator incorporating a shunt system.The 3176 does not have a cylinder block water cooling system. Instead, the cast water manifold in the spacer deck distributes 65% of the coolant volume to each of the cylinder liners and the remaining 35% flows directly to the cylinder head.The engine lubricating oil, which is both cooled and filtered, is supplied by a gear-type pump. Bypass valves provide unrestricted flow of lubrication oil to the engine parts when oil viscosity is high, or if either the oil cooler or the oil filter elements (paper cartridge) should become plugged.Multi-Torque Rating (if equipped)
This feature provides higher torque levels and better fuel economy while in top gear only. The 3176 electronics are able to determine when the vehicle is in top gear by calculating the engine rpm/vehicle speed ratio. A ratio of less than 26.6 will provide higher

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Group cross 101601-5723 ZEXEL

Hino 

 
220006980A 
INJECTION-PUMP ASSEMBLY
H07D-A
 
220006981A 
INJECTION-PUMP ASSEMBLY
H07D-A
 
220006981B 
INJECTION-PUMP ASSEMBLY
H07D-A
101601-5723  

101601-5724 
 
220006982A 
INJECTION-PUMP ASSEMBLY
H07D-A
F 019 Z10 493 
220006983A 
INJECTION-PUMP ASSEMBLY
H07D-A
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