101691-9913 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016919913


 

Information injection-pump assembly

ZEXEL 101691-9913 1016919913
101691-9913 INJECTION-PUMP ASSEMBLY
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Service parts 101691-9913 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 101069-3650
3. GOVERNOR 105921-2363
4. SUPPLY PUMP 105220-5690
5. AUTOM. ADVANCE MECHANIS 105614-3311
6. COUPLING PLATE 105661-0631
7. COUPLING PLATE
8. _
9. _
10. NOZZLE AND HOLDER ASSY 105101-5620
11. Nozzle and Holder 16600-95015
12. Open Pre:MPa(Kqf/cm2) 19.6{200}
13. NOZZLE-HOLDER 105031-4620
14. NOZZLE 105015-7360
15. NOZZLE SET

Include in #1:

101691-9913 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101691-9913 1016919913


Zexel num
Bosch num
Firm num
Name
101691-9913 
 
   
INJECTION-PUMP ASSEMBLY

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 opening pressure kPa   157 123 191
Overflow valve opening pressure kgf/cm2   1.6 1.25 1.95
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   3.7 3.65 3.75
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   -
Rack position   13.7
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   109 107.4 110.6
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   -
Rack position   9.8+-0.5
Pump speed r/min   275 275 275
Average injection quantity mm3/st.   9 7.2 10.8
Max. variation between cylinders %   0 -10 10
Fixing the rack   *
Standard for adjustment of the maximum variation between cylinders   *
Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.
 
Injection quantity adjustment_03
Adjusting point   A
Rack position   R1(13.7)
Pump speed r/min   1400 1400 1400
Average injection quantity mm3/st.   109 108 110
Basic   *
Fixing the lever   *
Boost pressure kPa   30.7 30.7
Boost pressure mmHg   230 230
Injection quantity adjustment_04
Adjusting point   B
Rack position   R1-0.1
Pump speed r/min   900 900 900
Average injection quantity mm3/st.   101.4 99.4 103.4
Fixing the lever   *
Boost pressure kPa   30.7 30.7
Boost pressure mmHg   230 230
Injection quantity adjustment_05
Adjusting point   C
Rack position   R2(12.6)
Pump speed r/min   400 400 400
Average injection quantity mm3/st.   61.6 59.6 63.6
Fixing the lever   *
Boost pressure kPa   0 0 0
Boost pressure mmHg   0 0 0
Injection quantity adjustment_06
Adjusting point   I
Rack position   -
Pump speed r/min   150 150 150
Average injection quantity mm3/st.   85 85 105
Fixing the lever   *
Rack limit   *
Boost compensator adjustment
Pump speed r/min   600 600 600
Rack position   R3(12)
Boost pressure kPa   4 2.7 5.3
Boost pressure mmHg   30 20 40
Boost compensator adjustment_02
Pump speed r/min   600 600 600
Rack position   R3+0.4
Boost pressure kPa   9.3 8 10.6
Boost pressure mmHg   70 60 80
Boost compensator adjustment_03
Pump speed r/min   600 600 600
Rack position   R1-0.6
Boost pressure kPa   17.3 17.3 17.3
Boost pressure mmHg   130 130 130
Timer adjustment
Pump speed r/min   920--
Advance angle deg.   0 0 0
Remarks
Start
 
Timer adjustment_02
Pump speed r/min   870
Advance angle deg.   0.5
Timer adjustment_03
Pump speed r/min   1400
Advance angle deg.   2 1.5 2.5
Remarks
Finish
 

Test data Ex:

Governor adjustment

Test data 101691-9913
N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B36 BCL=(1.1)+-0.1mm
----------

Speed control lever angle

Test data 101691-9913
F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=100mm
----------
a=26.5deg+-5deg b=42deg+-3deg

Stop lever angle

Test data 101691-9913
N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=36mm
----------
a=20deg+-5deg b=40deg+-5deg

Timing setting

Test data 101691-9913
(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(40deg)




Information:

The standard engine includes the features of programmable low idle and top engine limiting (TEL). Cruise control, PTO governing, vehicle speed limiting, low and high gears engine rpm limiting (progressive shift control), retarder coast/latch and idle shutdown timer are also available depending on OEM truck configurations.If equipped, the 3176 engine system is capable of being programmed for several customer specified parameters. These parameters are generally programmed so the vehicle will achieve optimum fuel efficiency and operator convenience.Low idle and top engine rpm limits are customer programmable to promote maximum fuel efficiency. The 3176 system allows the owner to select power ratings within a "family" to more efficiently match the vehicle to the application.The customer specified parameters and a brief explanation of each are as follows:1. Engine Power Rating - The 3176 engine is designed to provide full rated power over a large range of engine speeds. For example, the Caterpillar 3176 ATAAC Truck Engine ratings for the 19911 are:* 250 hp (187 kW) @ 1800 rpm* 275 hp (205 kW) @ 1800 rpm* 300 hp (224 kW) @ 1800 rpm* 325 hp (242 kW) @ 1800 rpm* 250 hp (187 kW) @ 2100 rpm* 275 hp (205 kW) @ 2100 rpm* 300 hp (224 kW) @ 2100 rpm* 325 hp (242 kW) @ 2100 rpm1These ratings are available factory-set from Caterpillar, they are EPA, CARB (50-state) and Canada emission certified. Other ratings may be programmed either at the OEM or in the field.2. Vehicle Identification Number - The owner's description, or unit number of the vehicle. 3. PTO Vehicle Speed Limit (PTO VSL) - Maximum vehicle speed at which the PTO Governor will function.4. PTO Engine RPM Limit (PTO RPM) - Maximum engine rpm attainable using the CRUISE CONTROL switches while the vehicle is operated below the PTO VSL (generally used for maximum rpm limit for overnight idling). 5. Low Gears #1 RPM Limit (LoGr #1) - The rpm at which the engine is limited in the lowest gears.6. Low Gears #2 RPM Limit (LoGr #2) - The rpm at which the engine is limited in a secondary gear range.7. Low Gears Turn Off Speed (LoGr Off Limits) - The vehicle speeds at which LoGr #1 and LoGr #2 turn off. 8. High Gears rpm Limit (HiGr rpm) - The rpm at which the engine is limited in the higher gears (generally used to encourage shifting into higher gears).9. High Gear Turn On Speed (HiGr On) - The vehicle speed at which High Gear rpm is in effect.10. Top Engine Limit (TEL) - Maximum allowable engine rpm generally set at rated rpm [rpm at which maximum power is developed] plus (+) 20 rpm. 11. Engine rpm at Vehicle Speed Limit (Eng rpm at VSL) - The engine rpm achieved in high (top) gear at VSL. Interruption of the vehicle speed input to the 3176 System will limit engine rpm to this value at all vehicle speeds.12. Vehicle Speed Limit (VSL) - Maximum vehicle speed.13. Low Engine Idle rpm

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