101693-9340 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016939340

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101693-9340 1016939340

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Service parts 101693-9340 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101069-3770

3. GOVERNOR 105921-4450

4. SUPPLY PUMP 105220-5800

5. AUTOM. ADVANCE MECHANIS 105690-0210

6. COUPLING PLATE 105661-0800

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7120

11. Nozzle and Holder 16600Z5578

12. Open Pre:MPa(Kqf/cm2) 16.7(170)/21.6(220)

13. NOZZLE-HOLDER 105030-4140

14. NOZZLE

105015-8680

15. NOZZLE SET

Include in #1:

101603-6751 as _

101693-9340 as INJECTION-PUMP ASSEMBLY

Cross reference number

ZEXEL 101693-9340 1016939340

Zexel num

Bosch num

Firm num

Name

101693-9340

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 134424-1520

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

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.9 3.85 3.95

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 13.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 99 97 101

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 9.7+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 8 6.2 9.8

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(13.3)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 99 98 100

Basic *

Fixing the lever *

Boost pressure kPa 26.7 26.7

Boost pressure mmHg 200 200

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.1

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 105.1 101.9 108.3

Fixing the lever *

Boost pressure kPa 26.7 26.7

Boost pressure mmHg 200 200

Injection quantity adjustment_05

Adjusting point C

Rack position R1-2

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 56.9 54.9 58.9

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. 80 80 100

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R1-2

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(13.3)

Boost pressure kPa 13.3 13.3 13.3

Boost pressure mmHg 100 100 100

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT (4)Boost compensator stroke: BCL
----------
T1=E91 BCL=2+-0.1mm
----------

Timer adjustment

(1)Adjusting range (2)Step response time (N): Speed of the pump (L): Load (theta) Advance angle (Srd1) Step response time 1 (Srd2) Step response time 2 1. Adjusting conditions for the variable timer (1)Adjust the clearance between the pickup and the protrusion to L.
----------
L=1.5+-0.2mm N3=800r/min C3=(6.5deg) t1=2--sec. t2=2--sec.
----------
N1=1200++r/min N2=1400r/min P1=0kPa(0kgf/cm2) P2=392kPa(4kgf/cm2) C1=2.5--deg C2=6.5+-0.4deg R01=0/4load R02=4/4load

Speed control lever angle

F:Full speed I:Idle (1)R = aa (2)Stopper bolt set position 'H'
----------
aa=36mm
----------
a=26.5deg+-5deg b=44deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=20deg+-5deg b=40deg+-5deg

0000001501 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack limit adjustment (1)Fix the rack at the rack limit position Ra. (2)Install the shim (D) to the rod (C) and tighten nut (E). (3)Select a shim (D) so that the distance between the end surface of the pump and the nut (E) is L. (4)Release the rack fixing and mount the joint (B) and fix. (5)At this time, confirm that the shim (D) does not interfere with the joint (B). 2. Rack sensor adjustment (-0420) (1)Screw in the bobbin (A) until it contacts the joint (B). (2)Fix the speed control lever at the full side. (3)Set the speed to N1 r/min. (4)Adjust the depth that the bobbin (A) is screwed in so that the control unit's rack sensor output voltage is VR+-0.01 (V), then tighten the nut (F). (5)Adjust the bobbin (A) so that the rack sensor's output voltage is VR. (6)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
L=33-0.2mm N1=700r/min Ra=R1(13.3)mm
----------

Timing setting

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

----------
a=(60deg)

Information:

Diagnostic Code 52 ECM or Personality Module Fault
Conditions Which Generate This Code:
The Electronic Control Module (ECM) has detected a fault in the Personality Module (PM), the ECM itself or the connector between them.System Response:
Diagnostic Code 52 is current (Diagnostic Lamp, ECAP or DDT) and is LOGGED in memory.Troubleshooting:
Refer to P-220: ECM And Personality Module Test.Diagnostic Code 53 ECM Fault
Conditions Which Generate This Code:
The ECM has detected an internal fault.System Response:
Diagnostic Code 53 is current (Diagnostic Lamp, ECAP, or DDT), and is LOGGED in memory.Troubleshooting:
The ECM must be replaced.Diagnostic Code 55 No Detected Faults
Conditions Which Generate This Code:
There are no ACTIVE Diagnostic Codes in the 3176 System.System Response:
Normal engine operation.Troubleshooting:
Diagnostic Code 55 does NOT indicate a 3176 System fault. It only shows that the system is operating correctly. The ECAP will display a Code 55 if no faults are currently ACTIVE. The Diagnostic Lamp will also flash Code 55 (on demand) if no faults have occurred since power-up.Diagnostic Code 56 Check Customer Or System Parameters
Conditions Which Generate This Code:
One or more of the Customer Specified Parameters and/or System Configuration Parameters are not correctly programmed for the system. Diagnostic Code 56 will be generated if the Electronic Control Module (ECM) has been replaced and any of the parameters have not been programmed.System Response:
1. Diagnostic Code 56 is current (Diagnostic Lamp, ECAP, or DDT), but is NOT LOGGED in memory.2. Engine power may be limited and/or the ECM may limit engine speed to low idle, depending on the parameter causing the Code 56.Troubleshooting:
1. Using an ECAP, read the parameters that triggered the code, shown along with the Diagnostic Code 56 on the " Current Diagnostic Messages" screen.2. Reprogram the displayed parameter(s). Refer to "Programming 3176 Parameters" in Section 2 of this manual.Diagnostic Code 57 Parking Brake Switch Fault
Conditions Which Generate This Code:
1. The Parking Brake Switch indicates the parking brake is ON.-AND-2. Diagnostic Code 36 (Vehicle Speed Signal Out Of Range) is NOT ACTIVE.-AND-3. The ECM reads a vehicle speed greater than 10 mph for at least five seconds.System Response:
1. Diagnostic Code 57 is current (Diagnostic Lamp, ECAP, or DDT), and IS LOGGED in memory.-AND-2. The Idle Shutdown Timer is disabled.Troubleshooting:
Follow P-216: Parking Brake Switch Test, in this manual.Diagnostic Code 63 Low Fuel Pressure Warning
Conditions Which Generate This Code:
1. The engine has been running at least 20 seconds.-AND-2. Diagnostic Code 37 (Fuel Pressure Sensor Fault) is not ACTIVE.-AND-3. Fuel pressure falls below the minimum specified for a given rpm for at least two minutes. Refer to the Chart below for minimum fuel pressure vs. rpm.System Response:
1. Diagnostic Code 63 is current (Diagnostic Lamp, ECAP, or DDT) and is LOGGED in memory.Troubleshooting:
1. Diagnostic Code 63 does NOT indicate a 3176 System fault. It only gives warning that a low fuel pressure condition exists.2. Use the procedures in the "Fuel System Inspection" and "Fuel Transfer Pump" sections of the 3176 Systems Operation Testing And Adjusting Manual, Form SENR3909, to determine the cause of the low fuel pressure condition. Diagnostic Code 72 Cylinder 1