101607-1161 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016071161

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101607-1161 1016071161

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Buy INJECTION-PUMP ASSEMBLY 101607-1161 zexel genuine, new aftermarket engine parts with delivery

Service parts 101607-1161 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101061-8280

3. GOVERNOR 105931-7540

4. SUPPLY PUMP 105210-4661

5. AUTOM. ADVANCE MECHANIS 105643-0760

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-7140

11. Nozzle and Holder ME076615

12. Open Pre:MPa(Kqf/cm2) 15.7{160}/21.6{220}

13. NOZZLE-HOLDER 105030-4290

14. NOZZLE

105015-8480

15. NOZZLE SET

Include in #1:

101607-1161 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-6572 as _

Cross reference number

ZEXEL 101607-1161 1016071161

Zexel num

Bosch num

Firm num

Name

101607-1161

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 131424-5520

Overflow valve opening pressure kPa 255 221 289

Overflow valve opening pressure kgf/cm2 2.6 2.25 2.95

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)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

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

Pre-stroke mm 3.2 3.15 3.25

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-5 deg. 60 59.5 60.5

Difference between angles 2
Cal 1-3 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cyl.1-2 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-4 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.6

Pump speed r/min 850 850 850

Each cylinder's injection qty mm3/st. 72.5 70.3 74.7

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 275 275 275

Each cylinder's injection qty mm3/st. 8.3 7.1 9.5

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.6)

Pump speed r/min 850 850 850

Average injection quantity mm3/st. 72.5 71.5 73.5

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.15

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 79.5 75.5 83.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point C

Rack position R1+0.65

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 71.5 67.5 75.5

Fixing the lever *

Timer adjustment

Pump speed r/min 1150

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1200

Advance angle deg. 0.9 0.4 1.4

Timer adjustment_03

Pump speed r/min 1380

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT
----------
T1=F24
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=29mm
----------
a=10deg+-5deg b=(44deg)+-3deg

Stop lever angle

N:Engine manufacturer's normal use S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection. (2)After setting the stopper bolt, confirm non-injection at speed cc. Rack position = dd (non-injection rack position). (3)Rack position = approximately ee. (4)Free (at shipping)
----------
aa=1400r/min bb=6.9-0.5mm cc=275r/min dd=(8.9)-0.5mm ee=15mm
----------
a=36.5deg+-5deg b=(25deg) c=13.5deg+-5deg

0000001201

F:At operation, hold it in the full speed position. I:Idle (1)At rack position aa and pump speed bb, set the stopper bolt. (After setting it, apply red paint.) (2)Actual measurement
----------
aa=7.15mm bb=1550+-10r/min
----------
a=15deg+-5deg

0000001501 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=400r/min Ra=9.2+-0.1mm
----------

Timing setting

(1)Pump vertical direction (2)Position of timer's tooth at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=11deg
----------
a=(0deg)

Information:

If the vehicle has a disconnect switch, the starting circuit can operate only after the disconnect switch is put in the ON position.The starting circuit is in operation only when the start switch is activated.The low amperage circuit and the charging circuit are both connected to the same side of the ammeter. The starting circuit connects to the opposite side of the ammeter.
Never operate the alternator without the battery in the circuit. Making or breaking an alternator connection with heavy load on the circuit can cause damage to the regulator.
Charging System Components
Alternator
Alternator Components (Typical Example)
(1) Brush holder. (2) Rear frame. (3) Rotor. (4) Stator. (5) Drive end frame. (6) Fan assembly. (7) Slip rings. (8) Rectifier.The alternator has three phase, full-wave, rectified output. It is a brush type alternator.The alternator is an electrical and mechanical component driven by a belt from engine rotation. It is used to charge the storage battery during engine operation. The alternator is cooled by a fan that is a part of the alternator. The fan pulls air through holes in the back of the alternator. The air exits the front of the alternator, cooling it in the process.The alternator converts mechanical and magnetic energy to alternating current (AC) and voltage. This process is done by rotating a direct current (DC) electromagnetic field (rotor) inside a three phase stator. The alternating current and voltage (generated by the stator) are changed to direct current by a three phase, full wave rectifier system using six silicone rectifier diodes. The alternator also has a diode trio which is an assembly made up of three exciter diodes. The diode trio rectifies field current needed to start the charging process. Direct current flows to the alternator output terminal.A solid state regulator is installed in the back of the alternator. Two brushes conduct current, through two slip rings, to the field coil on the rotor.There is also a capacitor mounted in the back of the alternator. The capacitor protects the rectifier from high voltages. It also suppresses radio noise.Regulator
The voltage regulator is a solid state (transistor, stationary parts) electronic switch which controls the alternator output. The regulator limits the alternator voltage to a preset value by controlling the field current. It feels the voltage in the system and switches "ON" and "OFF" many times a second to control the field current (DC current to the field windings) for the alternator to make the needed voltage output. Refer to Service Manual, SENR3862, for detailed service information for the Delco Remy 27 SI Series Alternator. For engines which have the alternator connected to an engine component, the ground strap must connect that component to the frame or to the battery ground.Starting System Components
Starter Solenoid
A solenoid is a magnetic switch that does two basic operations:1. Closes the high current starter motor circuit with a low current start switch circuit.2. Engages the starter motor pinion with the ring gear.
Typical SolenoidThe solenoid switch is made of an electromagnet (one or two sets of windings) around