101401-9490 ZEXEL 9 400 610 428 BOSCH INJECTION-PUMP ASSEMBLY 9400610428 1014019490 1670017d01

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 428 9400610428

ZEXEL 101401-9490 1014019490

NISSAN-DIESEL 1670017D01 1670017d01

Service parts 101401-9490 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101041-9120

3. GOVERNOR 105921-8310

4. SUPPLY PUMP 105220-7060

5. AUTOM. ADVANCE MECHANIS 105671-0490

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6170

11. Nozzle and Holder 16600-17D02

12. Open Pre:MPa(Kqf/cm2) 19.6{200}

13. NOZZLE-HOLDER 105048-3691

14. NOZZLE 105017-2010

15. NOZZLE SET

Include in #1:

101401-9490 as INJECTION-PUMP ASSEMBLY

106672-3790 as _

106672-3791

Cross reference number

BOSCH 9 400 610 428 9400610428

ZEXEL 101401-9490 1014019490

NISSAN-DIESEL 1670017D01 1670017d01

Zexel num

Bosch num

Firm num

Name

101401-9490
101401-9670

9 400 610 428

1670017D01 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD46T K

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 134424-4120

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)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-3-4-2

Pre-stroke mm 3.2 3.15 3.25

Rack position
Point A R=A

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point -

Rack position 13.6

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 92 90.4 93.6

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 H

Rack position 9.7+-0.5

Pump speed r/min 325 325 325

Average injection quantity mm3/st. 13 11.2 14.8

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.6)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 92 91 93

Basic *

Fixing the lever *

Boost pressure kPa 97.3 97.3

Boost pressure mmHg 730 730

Injection quantity adjustment_04

Adjusting point B

Rack position R1+1.05

Pump speed r/min 1550 1550 1550

Average injection quantity mm3/st. 113.5 109.5 117.5

Fixing the lever *

Boost pressure kPa 97.3 97.3

Boost pressure mmHg 730 730

Injection quantity adjustment_05

Adjusting point C

Rack position R2-1

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 55.5 51.5 59.5

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2-1

Boost pressure kPa 13.3 12 14.6

Boost pressure mmHg 100 90 110

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2(R1-0. 35)

Boost pressure kPa 84 84 84

Boost pressure mmHg 630 630 630

Timer adjustment

Pump speed r/min 900--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 850

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 5.5 5.2 5.8

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerances for racks not indicated: +-0.05mm. (3)Boost compensator stroke: BCL
----------
T1=L12 BCL=1+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H' (2)Use the hole at R = aa
----------
aa=32mm
----------
a=71deg+-5deg b=41deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=12mm
----------
a=29deg+-5deg b=10deg+-5deg

0000001501 POTENTIO METER

(A) : Governor plan view (B): Potentiometer harness terminal (C): Potentiometer connection diagram (D) : Output voltage standard value (S): Voltage P/M: potentiometer (v): output voltage (V) (p): direction of potentiometer rotation 1. Adjustment procedures (1)Apply DCV1 to potentiometer harness terminal (B) to obtain the specified output voltage. (2)Fix the speed lever at the full side. (3)Loosen the bolt (S), and move the potentiometer from left and right. (4)Adjust so that the output voltage at full is within the standard values. (5)Fix bolt (S). (6)Repeatedly move the speed lever from the full side to the idle side. (7)Check that it is within the standard values at full and idle.
----------
V1=5+-0.02V
----------
V1=5+-0.02V Va=(5)V Vb=4+-0.2V Vc=0.58+-0.3V

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear's distinguishing mark) at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=5deg
----------
a=(50deg)