107692-0620 ZEXEL 9 400 618 982 BOSCH INJECTION-PUMP ASSEMBLY 9400618982 1076920620 1671395263

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 618 982 9400618982

ZEXEL 107692-0620 1076920620

NISSAN-DIESEL 1671395263 1671395263

Service parts 107692-0620 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-1200

3. GOVERNOR 105921-6480

4. SUPPLY PUMP 105237-6140

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105663-0660

7. COUPLING PLATE 156638-3020

8. _ 159590-3620

9. _

10. NOZZLE AND HOLDER ASSY 105101-7231

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/21.6{220}

13. NOZZLE-HOLDER 105030-4390

14. NOZZLE 105015-8870

15. NOZZLE SET

Include in #1:

107692-0620 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 982 9400618982

ZEXEL 107692-0620 1076920620

NISSAN-DIESEL 1671395263 1671395263

Zexel num

Bosch num

Firm num

Name

107692-0620

9 400 618 982

1671395263 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
NE6TA 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 131425-0520

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

PS/ACT control unit part no. 407910-3 03*

Selector switch no. 01

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 15

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 5.6 5.57 5.63

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Adjusting point -

Rack position 15.2

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 118.6 116.6 120.6

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 8.5+-0.5

Pump speed r/min 670 670 670

Average injection quantity mm3/st. 9.5 7.7 11.3

Max. variation between cylinders % 0 -10 10

Fixing the rack *

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(15.2)

Pump speed r/min 1400 1400 1400

Average injection quantity mm3/st. 118.6 117.6 119.6

Basic *

Fixing the lever *

Boost pressure kPa 73.3 73.3

Boost pressure mmHg 550 550

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_04

Adjusting point B

Rack position R1-1.35

Pump speed r/min 1100 1100 1100

Average injection quantity mm3/st. 106.6 102.6 110.6

Fixing the lever *

Boost pressure kPa 73.3 73.3

Boost pressure mmHg 550 550

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-2.3)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 97.5 93.5 101.5

Fixing the lever *

Boost pressure kPa 73.3 73.3

Boost pressure mmHg 550 550

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Injection quantity adjustment_06

Adjusting point D

Rack position R2(R1-4)

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 67.4 66.4 68.4

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.25+-0. 01

PS407980-224* mm 3.6+-0.0 3

PS407910-303* V 2.25+-0. 01

PS407910-303* mm 3.6+-0.0 3

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R2(R1-4)

Boost pressure kPa 26.7 22.7 30.7

Boost pressure mmHg 200 170 230

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R2+0.7

Boost pressure kPa 46.7 45.4 48

Boost pressure mmHg 350 340 360

Boost compensator adjustment_03

Pump speed r/min 700 700 700

Rack position (R1-2.9)

Boost pressure kPa 60 60 60

Boost pressure mmHg 450 450 450

0000001601

CU407980-224* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_02

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

_03

CU407980-224* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

_04

CU407910-303* *

Actuator retarding type *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 2.5 2.45 2.55

Output voltage V 2.83 2.82 2.84

Adjustment *

_05

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Pre-stroke mm 5.6 5.57 5.63

Output voltage V 1.2 1 1.4

Confirmation *

_06

CU407910-303* *

Supply voltage V 12 11.5 12.5

Ambient temperature degC 23 18 28

Output voltage V 3.05 3.05

Confirmation of operating range *

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=G00 BCL=(1.1)+-0.1mm
----------

Speed control lever angle

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

----------
a=24deg+-5deg b=(37deg)+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Set the stopper bolt at pump speed = aa and rack position = bb (non-injection rack position). Confirm non-injection.
----------
aa=1400r/min bb=5-0.5mm
----------
a=20deg+-5deg b=37deg+-5deg

0000001301

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
----------
aa=5.6+-0.03mm
----------
a=(60deg)

0000001401

(1)Pointer (2)Injection timing aligning mark (3)Fly weight (4)The actual shape and direction may be different from this illustration. Operation sequence 1. Turn the prestroke actuator OFF. 2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position. 3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching. 4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark. 5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
----------

----------

0000001701

A : Stopper pin B: Connector
----------

----------

0000001801

C:Shim
----------

----------

0000001901

A:Sealing position B:Pre-stroke actuator 1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side). Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m) 2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it. Tightening torque: 7^9 N.m (0.7^0.9 kgf.m) 3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------

----------

0000002201 SPEED SENSOR

(A) Flyweight projection (B) Pickup sensor (c) Lock nut Speed sensor installation (1)Install the speed sensor so that the clearance between the sensor and the flyweight projection is L. (This gap is the gap when the pickup sensor is returned 1 turn from where it contacts the flyweight tooth.)
----------
L=0.8~1mm
----------

0000002301 RACK SENSOR

(VR) measurement voltage (I) Part number of the control unit (G) Apply red paint. (H): End surface of the pump 1. Rack sensor adjustment (-0620) (1)Fix the speed control lever at the full position (2)Set the speed to N1 r/min. (If the boost compensator is provided, apply boost pressure.) (3)Adjust the bobbin (A) so that the rack sensor's output voltage is VR+-0.01. (4)At that time, rack position must be Ra. (5)Apply G at two places. Connecting part between the joint (B) and the nut (F) Connecting part between the joint (B) and the end surface of the pump (H)
----------
N1=1400r/min Ra=R1(15.2)mm
----------

0000002401 MICRO SWITCH

Adjustment of the micro-switch Adjust the bolt to obtain the following lever position when the micro-switch is ON. (1)Speed N1 (2)Rack position Ra
----------
N1=375r/min Ra=8.5+-0.1mm
----------

0000002501 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 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=1400r/min L1=1.5+-0.5mm L2=24+-0.5mm h1=0.15mm
----------
Ra=R1(15.2)mm Rb=R1-0.5mm Pa=79.4+-2.7kPa(596+-20mmHg) Pb=58.7+-0.7kPa(440+-5mmHg) Q1=118.6+-1cm3/1000st Q2=(109.3)cm3/1000st