106671-5990 ZEXEL 9 400 616 894 BOSCH INJECTION-PUMP ASSEMBLY 9400616894 1066715990 1671496519

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 616 894 9400616894

ZEXEL 106671-5990 1066715990

NISSAN-DIESEL 1671496519 1671496519

Cross reference number

BOSCH 9 400 616 894 9400616894

ZEXEL 106671-5990 1066715990

NISSAN-DIESEL 1671496519 1671496519

Zexel num

Bosch num

Firm num

Name

106671-5990

9 400 616 894

1671496519 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PE6TE 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 3.65 3.6 3.7

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 10.9

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 149 147 151

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Boost pressure kPa 65.3 65.3

Boost pressure mmHg 490 490

Solenoid boost comp. OFF *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.7+-0.5

Pump speed r/min 270 270 270

Average injection quantity mm3/st. 15.5 14.5 16.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Solenoid boost comp. OFF *

Injection quantity adjustment_03

Adjusting point D

Rack position 9.7

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 109 106 112

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Solenoid boost comp. OFF *

Boost compensator adjustment

Pump speed r/min 400 400 400

Rack position 9.7

Boost pressure kPa 18.7 17.4 20

Boost pressure mmHg 140 130 150

Boost compensator adjustment_02

Pump speed r/min 400 400 400

Rack position 10.9

Boost pressure kPa 38.7 34.7 42.7

Boost pressure mmHg 290 260 320

Boost compensator adjustment_03

Pump speed r/min 400 400 400

Rack position (11.5)

Boost pressure kPa 52 52 52

Boost pressure mmHg 390 390 390

Timer adjustment

Pump speed r/min -

Advance angle deg. 0.5

Remarks
Measure the actual speed.

Timer adjustment_02

Pump speed r/min -

Advance angle deg. 1 0.5 1.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Solenoid boost compensator OFF: SBL (3)Rack limit using the stop lever: R1 (4)Boost compensator stroke: BCL (5)Damper spring setting (6)Variable speed specification: idling adjustment (7)Fix the lever at the full-load position at delivery. (8)Main spring setting
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SBL=(13.15)mm R1=12.9+0.2mm BCL=(1.8)mm
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Speed control lever angle

F:Full speed I:Idle (1)Pump speed = aa (2)Set the stopper bolt (fixed at full-load position at delivery.)
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aa=290r/min
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a=(16.5deg)+-5deg b=(8.5deg)+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
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aa=42mm
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a=28deg+-3deg b=45deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position aa (pump speed bb r/min ) (2)Use the pin above R = cc
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aa=12.9+0.2mm bb=250r/min cc=40mm
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a=(42.5deg)+-5deg b=(41.5deg)+-5deg

0000001501 BCS

(A) Screw for precise adjustment (B) Pre-adjustment screw (C) Control rack, rack decrease direction (D) Rack limit 1. Solenoid boost compensator adjustment (1)Supply DC: V1 to the solenoid terminals and confirm solenoid operation. (2)With the solenoid ON, calculate L1 from the value of R1. [L1 = La - (10.5 - R1) +-0.2] (3)Adjust (B) to obtain L1. (4)Assemble the solenoid to the governor. (5)With the solenoid ON, readjust (B) so that R1 is within the allowance a. (6)With the solenoid OFF, perform all governor adjustments except rack limit adjustment. (7)Set the pump speed at N1 and turn the solenoid ON. (8)Adjust (A) so that R1 is within the allowance range a. (9)Set the pump speed at N1 and fix the load lever in the full position (10)Turn the solenoid switch ON and OFF several times and confirm that the difference in rack positions is within L2. (11)Set the rack limit. (12)Stamp the solenoid valve.
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V1=24V N1=400r/min N2=0r/min R1=9.15mm a=+-0.5mm La=28mm L1=26.65+-0.2mm L2=3.5~5mm
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0000001601 TAMPER PROOF

Tamperproofing-equipped boost compensator cover installation procedure (A): After adjusting the boost compensator, assemble then tighten the bolts to remove the heads. (B): Specified torque (1)Before adjusting the governor and the boost compensator, tighten the screw to the specified torque. (Tightening torque T = T1 maximum) (2)After adjusting the governor and the boost compensator, tighten to the specified torque to break off the bolt heads. (Tightening torque T = T2)
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T1=2.5N-m(0.25kgf-m) T2=2.9~4.4N-m(0.3~0.45kgf-m)
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