Information injection-pump assembly
ZEXEL
101603-2321
1016032321
HINO
220204721A
220204721a
Rating:
Service parts 101603-2321 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
23600-2820A
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Cross reference number
ZEXEL
101603-2321
1016032321
HINO
220204721A
220204721a
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
134424-0920
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
4.8
4.77
4.83
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Adjusting point
A
Rack position
10
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
114.5
113
116
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Fixing the lever
*
Boost pressure
kPa
28.7
28.7
Boost pressure
mmHg
215
215
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-0.5
Pump speed
r/min
410
410
410
Average injection quantity
mm3/st.
9
8
10
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
-
Pump speed
r/min
100
100
100
Average injection quantity
mm3/st.
135
135
145
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Rack limit
*
Boost compensator adjustment
Pump speed
r/min
800
800
800
Rack position
R1-0.85
Boost pressure
kPa
9.3
8
10.6
Boost pressure
mmHg
70
60
80
Boost compensator adjustment_02
Pump speed
r/min
800
800
800
Rack position
R1(10)
Boost pressure
kPa
18
14
22
Boost pressure
mmHg
135
105
165
Timer adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
1.5
1.2
1.8
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Target notch: K
(2)Tolerance for racks not indicated: +-0.05mm.
(3)RACK LIMIT
(4)Set idle sub-spring
(5)Boost compensator stroke: BCL
(6)Main spring setting
----------
K=13 BCL=0.85+-0.1mm
----------
----------
K=13 BCL=0.85+-0.1mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt setting
----------
----------
a=(6deg)+-5deg b=(20deg)+-5deg
----------
----------
a=(6deg)+-5deg b=(20deg)+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Pump speed aa and rack position bb (to be sealed at delivery)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
----------
aa=0r/min bb=1-0.5mm
----------
a=21deg+-5deg b=(55deg)
Timing setting
(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(50deg)
----------
----------
a=(50deg)
Information:
Diagnostic Code 35 Engine Overspeed Warning
Conditions Which Generate This Code:The Electronic Control Module (ECM) detects an engine speed greater than 3300 rpm. System Response:1. Diagnostic Code 35 is current (Diagnostic Lamp, ECAP, or DDT) and is LOGGED in memory. -AND-2. The 3176 System will attempt to limit engine rpm to Top Engine Limit (TEL) by not allowing the unit injectors to inject fuel. The injectors are shut off because the engine is running at a speed that exceeds rated rpm. A diagnostic code 35 has no effect on performance. Troubleshooting:Diagnostic Code 35 warns of an overspeed condition and is for information only. It does not indicate a fault in the 3176 System.Factory passwords are required to clear a diagnostic code 35.Diagnostic Code 37 Fuel Pressure Sensor Fault
Conditions Which Generate This Code:Fuel Pressure Sensor signal voltage drops below 0.2 volts DC or rises above 4.7 volts DC for at least ten seconds. System Response:1. Diagnostic Code 37 is current (Diagnostic Lamp, ECAP, or DDT) and is LOGGED in memory.2. Electronic Control Module (ECM) "Fuel Pressure" reading is set to 0 kPa (0 psi) when fault is active.3. Engine operation is NOT affected. Troubleshooting:Follow P-226: Fuel Pressure Sensor Test, in this manualDiagnostic Code 42 Check Sensor Calibrations
On new (replacement) Electronic Control Modules (ECM), Diagnostic Code 42 will appear until sensors have been calibrated. Conditions Which Generate This Code:1. The Speed/Timing Sensor is not correctly calibrated, -AND/OR-2. The Boost Pressure Sensor is not correctly calibrated. System Response:1. Diagnostic Code 42 is current (Diagnostic Lamp, ECAP, or DDT) but is NOT LOGGED in memory.2. If Speed/Timing Sensor is not correctly calibrated, injection timing will default to base timing.3. If Boost Pressure Sensor is not correctly calibrated, then boost pressure is set to 0 kPa (0 psi) by the ECM. This will limit fuel delivery rate which in turn will limit engine horsepower. Troubleshooting:1. Use an ECAP or DDT to calibrate the Boost Pressure Sensor. Follow P-302: Boost Pressure Sensor Calibration, in this manual.2. Only an ECAP can be used to calibrate the Speed/Timing Sensor. Follow P-301: Speed/Timing Sensor Calibration, in this manual or "Calibrating Injection Timing" in the 3176 Vehicular Diesel Engine, Systems Operation Testing And Adjusting Manual, Form SENR4964.Diagnostic Code 51 Intermittent Battery Power To ECM
Conditions Which Generate This Code:Battery voltage to the Electronic Control Module (ECM) momentarily drops below six volts DC. Quickly turning the key off, then back on, may cause a Code 51 to be generated. System Response:1. Diagnostic Code 51 is current (Diagnostic Lamp, ECAP, or DDT) and remains active as long as the key is ON. Fault is LOGGED in memory only if the fault occurs while the engine is running.2. Interruption of electrical power may result in a brief loss of engine power or a complete engine shutdown, depending on the duration of the electrical power loss. Troubleshooting:Follow P-210: Electrical Power Supply Test, in this manual.Diagnostic Code 52 ECM or Personality Module Fault
Conditions Which Generate This Code:The Electronic Control Module (ECM) has detected a fault
Conditions Which Generate This Code:The Electronic Control Module (ECM) detects an engine speed greater than 3300 rpm. System Response:1. Diagnostic Code 35 is current (Diagnostic Lamp, ECAP, or DDT) and is LOGGED in memory. -AND-2. The 3176 System will attempt to limit engine rpm to Top Engine Limit (TEL) by not allowing the unit injectors to inject fuel. The injectors are shut off because the engine is running at a speed that exceeds rated rpm. A diagnostic code 35 has no effect on performance. Troubleshooting:Diagnostic Code 35 warns of an overspeed condition and is for information only. It does not indicate a fault in the 3176 System.Factory passwords are required to clear a diagnostic code 35.Diagnostic Code 37 Fuel Pressure Sensor Fault
Conditions Which Generate This Code:Fuel Pressure Sensor signal voltage drops below 0.2 volts DC or rises above 4.7 volts DC for at least ten seconds. System Response:1. Diagnostic Code 37 is current (Diagnostic Lamp, ECAP, or DDT) and is LOGGED in memory.2. Electronic Control Module (ECM) "Fuel Pressure" reading is set to 0 kPa (0 psi) when fault is active.3. Engine operation is NOT affected. Troubleshooting:Follow P-226: Fuel Pressure Sensor Test, in this manualDiagnostic Code 42 Check Sensor Calibrations
On new (replacement) Electronic Control Modules (ECM), Diagnostic Code 42 will appear until sensors have been calibrated. Conditions Which Generate This Code:1. The Speed/Timing Sensor is not correctly calibrated, -AND/OR-2. The Boost Pressure Sensor is not correctly calibrated. System Response:1. Diagnostic Code 42 is current (Diagnostic Lamp, ECAP, or DDT) but is NOT LOGGED in memory.2. If Speed/Timing Sensor is not correctly calibrated, injection timing will default to base timing.3. If Boost Pressure Sensor is not correctly calibrated, then boost pressure is set to 0 kPa (0 psi) by the ECM. This will limit fuel delivery rate which in turn will limit engine horsepower. Troubleshooting:1. Use an ECAP or DDT to calibrate the Boost Pressure Sensor. Follow P-302: Boost Pressure Sensor Calibration, in this manual.2. Only an ECAP can be used to calibrate the Speed/Timing Sensor. Follow P-301: Speed/Timing Sensor Calibration, in this manual or "Calibrating Injection Timing" in the 3176 Vehicular Diesel Engine, Systems Operation Testing And Adjusting Manual, Form SENR4964.Diagnostic Code 51 Intermittent Battery Power To ECM
Conditions Which Generate This Code:Battery voltage to the Electronic Control Module (ECM) momentarily drops below six volts DC. Quickly turning the key off, then back on, may cause a Code 51 to be generated. System Response:1. Diagnostic Code 51 is current (Diagnostic Lamp, ECAP, or DDT) and remains active as long as the key is ON. Fault is LOGGED in memory only if the fault occurs while the engine is running.2. Interruption of electrical power may result in a brief loss of engine power or a complete engine shutdown, depending on the duration of the electrical power loss. Troubleshooting:Follow P-210: Electrical Power Supply Test, in this manual.Diagnostic Code 52 ECM or Personality Module Fault
Conditions Which Generate This Code:The Electronic Control Module (ECM) has detected a fault