101601-5742 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016015742 220007001a


 

Information injection-pump assembly

ZEXEL 101601-5742 1016015742
HINO 220007001A 220007001a
101601-5742 INJECTION-PUMP ASSEMBLY
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Buy INJECTION-PUMP ASSEMBLY 101601-5742 zexel genuine, new aftermarket engine parts with delivery

Service parts 101601-5742 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101060-5230
3. GOVERNOR 105953-0081
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:

101601-5742 as INJECTION-PUMP ASSEMBLY

Include in #2:

Cross reference number

ZEXEL 101601-5742 1016015742
HINO 220007001A 220007001a


Zexel num
Bosch num
Firm num
Name
101601-5742 
101601-5743 
 
220007001A  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
RED3 control unit part number   407910-2 470
RED3 rack sensor specifications mm   15
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
Rack position   (8.8)
Vist V   2.24 2.24 2.24
Pump speed r/min   850 850 850
Average injection quantity mm3/st.   76.5 75.5 77.5
Max. variation between cylinders %   0 -3.5 3.5
Basic   *
Injection quantity adjustment_02
Rack position   (6.6)
Vist V   2.7 2.6 2.8
Pump speed r/min   250 250 250
Each cylinder's injection qty mm3/st.   15.5 14.5 16.5
Governor adjustment
Pump speed r/min   925--
Advance angle deg.   0 0 0
Load   1/4
Remarks
Start
 
Governor adjustment_02
Pump speed r/min   875
Advance angle deg.   0.3
Load   1/4
Governor adjustment_03
Pump speed r/min   (920--)
Advance angle deg.   1 0.7 1.3
Load   4/4
Governor adjustment_04
Pump speed r/min   1175+50
Advance angle deg.   1 0.7 1.3
Load   3/4
Governor 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:

Speed control lever angle

Test data 101601-5742
N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=1mm bb=16mm
----------
a=2deg+-5deg b=27deg+-5deg

0000000901

Test data 101601-5742
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

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

Stop lever angle

Test data 101601-5742
(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 15 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
----------

----------




Information:

Engine Performance
Poor vehicle performance is traditionally believed to be the result of a lack (or loss) of engine performance, when in fact the engine is only one of numerous factors that influence the overall performance of a vehicle. The previous section on fuel economy describes the factors that determine the power demand on an engine. The engine has no control over the demand made upon it by the vehicle or the operator.A vehicle that requires 225 hp (168 kW) to operate at 55 mph (88 km/h) will get worse fuel economy than a vehicle that requires only 175 hp (130 kW).These same factors also affect the amount of power available to perform additional work such as climb a grade or pass another vehicle. With a 310 hp (231 kW) engine, the first vehicle will have only 85 hp (63 kW) available to perform additional work compared to 135 hp (100 kW) on the second vehicle (mentioned above).If you feel you have a vehicle performance problem, first consider the impact of vehicle efficiency and operating characteristics (vehicle speed, design, etc.), on power demand before questioning engine performance. In the case of poor fuel economy, the engine is not likely to be the cause without the presence of excessive exhaust smoke and/or a significant loss of power.If you feel you have a valid engine performance problem, contact an authorized Caterpillar dealer for assistance. If your engine is under warranty, then the Caterpillar warranty or extended service coverage willcover the cost of resolving a valid engine performance deficiency.However, if the engine is not found at fault, all costs incurred will be the responsibility of the owner.
Adjustment of the fuel system outside Caterpillar specified limits will not improve fuel efficiency and can result in damage to the engine.
Performance Analysis Report (PAR)
PAR complements a good preventive maintenance program and Caterpillar recommends a regularly scheduled PAR analysis to monitor the condition and maintenance requirements of your engine and to ensure your engine is operating at peak efficiency.Potential problems can be identified early, thus preventing unnecessary repair costs and unscheduled downtime. Consult your Caterpillar dealer for complete information and assistance in establishing a PAR program for your engine.PAR reflects the results of various tests normally conducted by your Caterpillar dealer for the purpose of:* confirming your engine is operating efficiently and within specification.* identifying potential problems.* determining components or systems that should be adjusted, replaced, etc.Approximately 80 to 85% of your truck engine's operation and maintenance cost is the cost of the fuel. Therefore, substantial cost reductions can be achieved by keeping your engine operating at peak efficiency. The fuel economy and performance of the engine is affected by the truck specifications, how it is operated and the condition of the engine. Each plays an important part in minimizing your overall owning and operating cost.Caterpillar has an exclusive Performance Analysis Report (PAR) Program that can help you keep the engine portion of this equation up to PAR. The PAR Program uses a chassis dynamometer to

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