101641-9160 ZEXEL 9 400 610 066 BOSCH INJECTION-PUMP ASSEMBLY 9400610066 1016419160 16713l9002

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 610 066 9400610066

ZEXEL 101641-9160 1016419160

NISSAN-DIESEL 16713L9002 16713l9002

Service parts 101641-9160 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101064-9030

3. GOVERNOR 105931-1591

4. SUPPLY PUMP 105220-4860

5. AUTOM. ADVANCE MECHANIS 105622-0680

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-1210

11. Nozzle and Holder 16600-37502

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105071-1080

14. NOZZLE

105000-1010

15. NOZZLE SET

Include in #1:

101641-9160 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-3690 as _

104740-3692

104740-3693

Cross reference number

BOSCH 9 400 610 066 9400610066

ZEXEL 101641-9160 1016419160

NISSAN-DIESEL 16713L9002 16713l9002

Zexel num

Bosch num

Firm num

Name

101641-9160
101641-9240

9 400 610 066

16713L9002 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD33T * 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

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 2.3 2.25 2.35

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 13.5

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 47.3 46.2 48.4

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.9+-0.5

Pump speed r/min 365 365 365

Average injection quantity mm3/st. 9.2 8.1 10.3

Max. variation between cylinders % 0 -15 15

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(13.5)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 47.3 46.3 48.3

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Injection quantity adjustment_04

Adjusting point B

Rack position R1(13.5)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 48.7 44.7 52.7

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Injection quantity adjustment_05

Adjusting point C

Rack position R1-0.8

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 36.2 32.2 40.2

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position R1-0.8

Boost pressure kPa 10.7 10.7 15.4

Boost pressure mmHg 80 80 115

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position R1(13.5)

Boost pressure kPa 34.7 28 34.7

Boost pressure mmHg 260 210 260

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 700

Advance angle deg. 1

Timer adjustment_04

Pump speed r/min 1050

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 7.5 7 8

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT: RAL
----------
T1=89 RAL=13.8+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=0deg+-5deg b=37deg+-3deg

Stop lever angle

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

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

0000001501 RACK SENSOR

V1:Supply voltage Vf:Full side output voltage Vi:Idle side output voltage (a) Speed lever (B) Link (c) Nut (F) Full (I) Idle (P) Potentiometer 1. Load sensor adjustment (1)Apply DC5 = V1 voltage between potentiometer connector terminals (1) ~ (3) and measure the output voltage between (1) ~ (2). (2)Move the speed lever (A) until it contacts the full side stopper bolt and then turn the link (B) to adjust the potentiometer (P)'s output voltage to Vf. (3)Confirm that the speed lever (A) turns smoothly between idle (I) and Full (F) and tighten the nut (C). (Tightening torque: 3.4 ~ 4.9 N.m {0.35 ~ 0.5 kgf.m}) (4)Move the speed lever (A) several times between idle (I) and full (F) and confirm that the voltage is Vf when it contacts the full side stopper bolt and Vi when it contacts the idle side stopper bolt.
----------
V1=5+-0.02V Vf=4.8++V Vi=0.5+0.4-0.3V
----------

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(130deg)