106661-5512 ZEXEL 9 400 616 629 BOSCH INJECTION-PUMP ASSEMBLY 9400616629 1066615512 1671396900

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 616 629 9400616629

ZEXEL 106661-5512 1066615512

NISSAN-DIESEL 1671396900 1671396900

Service parts 106661-5512 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106066-1300

3. GOVERNOR 105487-5510

4. SUPPLY PUMP 105217-1850

5. AUTOM. ADVANCE MECHANIS 105614-4220

6. COUPLING PLATE 105662-0761

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-4570

11. Nozzle and Holder 1660096502

12. Open Pre:MPa(Kqf/cm2) 22.6{230}

13. NOZZLE-HOLDER 105031-4370

14. NOZZLE 105015-4170

15. NOZZLE SET

Include in #1:

106661-5512 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 616 629 9400616629

ZEXEL 106661-5512 1066615512

NISSAN-DIESEL 1671396900 1671396900

Zexel num

Bosch num

Firm num

Name

106661-5512

9 400 616 629

1671396900 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PE6T * 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 8-3-600

Overflow valve 132424-0620

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 1-4-2-6- 3-5

Pre-stroke mm 3.2 3.15 3.25

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 A

Rack position 11.5

Pump speed r/min 1150 1150 1150

Average injection quantity mm3/st. 153.3 150.3 156.3

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Remarks
Rack limit using stop lever.

Injection quantity adjustment_02

Adjusting point B

Rack position 11.5

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 153.6 150.6 156.6

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Remarks
Rack limit using stop lever.

Injection quantity adjustment_03

Adjusting point C

Rack position 11.5

Pump speed r/min 750 750 750

Average injection quantity mm3/st. 149.6 147.6 151.6

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Remarks
Rack limit using stop lever.

Injection quantity adjustment_04

Adjusting point D

Rack position 11.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 145.5 142.5 148.5

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 66.7 66.7

Boost pressure mmHg 500 500

Remarks
Rack limit using stop lever.

Injection quantity adjustment_05

Adjusting point E

Rack position 9.3

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 86.7 80.7 92.7

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point F

Rack position 6.1+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11 10 12

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 300 300 300

Rack position 9.3

Boost pressure kPa 12 12 12

Boost pressure mmHg 90 90 90

Boost compensator adjustment_02

Pump speed r/min 300 300 300

Rack position 10.9

Boost pressure kPa 40 38.7 41.3

Boost pressure mmHg 300 290 310

Boost compensator adjustment_03

Pump speed r/min 300 300 300

Rack position 11.5

Boost pressure kPa 53.3 53.3 53.3

Boost pressure mmHg 400 400 400

Timer adjustment

Pump speed r/min 700

Advance angle deg. 0.3

Timer adjustment_02

Pump speed r/min 750

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 850

Advance angle deg. 0.5 0.1 0.9

Timer adjustment_04

Pump speed r/min 1000

Advance angle deg. 1.7 1.3 2.1

Timer adjustment_05

Pump speed r/min 1150

Advance angle deg. 3 2.6 3.4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Boost compensator stroke: BCL (5)Rack limit using stop lever (6)Damper spring setting (7)Variable speed specification: idling adjustment (8)Main spring setting
----------
RT=1 TH=2mm BCL=2.2+-0.1mm
----------

Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Stopper bolt setting
----------
aa=225r/min
----------
a=11deg+4deg-3deg b=22deg+-4deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=32.5deg+-5deg b=42.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side (2)Use the hole at R = aa (3)Rack position bb (4)Rack position = cc (non-injection rack position)
----------
aa=50mm bb=11.5mm cc=1.9-0.5mm
----------
a=27.5deg+-5deg b=28deg+-3deg