101403-9200 ZEXEL 9 400 614 039 BOSCH INJECTION-PUMP ASSEMBLY 9400614039 1014039200 1670033d01

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 614 039 9400614039

ZEXEL 101403-9200 1014039200

NISSAN-DIESEL 1670033D01 1670033d01

Include in #1:

101605-9433 as _

Cross reference number

BOSCH 9 400 614 039 9400614039

ZEXEL 101403-9200 1014039200

NISSAN-DIESEL 1670033D01 1670033d01

Zexel num

Bosch num

Firm num

Name

101403-9200
101403-9220

9 400 614 039

1670033D01 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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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 13.4

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 88.5 86.9 90.1

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. 12 10.2 13.8

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(13.4)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 88.5 87.5 89.5

Basic *

Fixing the lever *

Boost pressure kPa 64 64

Boost pressure mmHg 480 480

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.45

Pump speed r/min 1550 1550 1550

Average injection quantity mm3/st. 91.5 87.5 95.5

Fixing the lever *

Boost pressure kPa 64 64

Boost pressure mmHg 480 480

Boost compensator adjustment

Pump speed r/min 500 500 500

Rack position R2-1.05

Boost pressure kPa 14.7 13.4 16

Boost pressure mmHg 110 100 120

Boost compensator adjustment_02

Pump speed r/min 500 500 500

Rack position R2(R1-0. 2)

Boost pressure kPa 50.7 50.7 50.7

Boost pressure mmHg 380 380 380

Timer adjustment

Pump speed r/min (N1+50)- -

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min N1

Advance angle deg. 0.5

Remarks
Measure the actual speed.

Timer adjustment_03

Pump speed r/min 1550

Remarks
Measure the actual advance angle.

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 7 6.5 7.5

Remarks
Measure the actual speed, stop

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)Boost compensator stroke: BCL
----------
T1=P14 BCL=1.05+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=32mm
----------
a=71deg+-5deg b=40deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa
----------
aa=15mm
----------
a=29deg+-5deg b=10deg+-5deg

0000001501 ACS

(A) Set screw (B) Push rod 1 (C) Push rod 2 (D) Cover 1. Aneroid compensator unit adjustment (1)Select the push rod 2 to obtain L2. (2)Screw in (A) to obtain L1. 2. Adjustment when mounting the governor. (1)Set the speed of the pump to N1 r/min and fix the control lever at the full set position. (2)Screw in the aneroid compensator to obtain the performance shown in the graph above. (3)As there is hysterisis, measure when the absolute pressure drops. (4)Hysterisis must not exceed rack position = h1.
----------
N1=1550r/min L1=1.5+-0.5mm L2=24+-0.5mm h1=0.15mm
----------
Ra=R3(R1+0.45)mm Rb=R3-0.25mm Pa=(89.3)+-2.7kPa((670)+-20mmHg) Pb=79.4+-0.7kPa(596+-5mmHg) Q1=(91.5)+-2cm3/1000st Q2=(86.5)+-2cm3/1000st

0000001601 ACS

(A) Aneroid compensator (B) Set screw (C) Boost pressure inlet (D) Rack positioning screw (E): Aneroid compensator main body (F) Boost compensator spring (G): Aneroid compensator spring (H): Adjusting notch (I) Push rod 1. Instructions for adjusting the boost compensator with the aneroid compensator (1)Select a pushrod to obtain L1 at full boost. (2)Remove the aneroid compensator main body. (3)Adjust the booster compensator stroke by turning the screw at (D. (4)Adjust the beginning of boost compensator operation by turning the notch at (H). (5)Install the aneroid compensator at full boost state. (6)Turn (B)'s set screw so that the distance between the snapring and the body is L2. (7)Screw in the aneroid compensator main body and adjust the point where it comes into play.
----------
L1=24+-0.5mm L2=1.5+-0.5mm
----------

Timing setting

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