107692-0660 ZEXEL 9 400 618 986 BOSCH INJECTION-PUMP ASSEMBLY 9400618986 1076920660 1671395267


107692-0660 INJECTION-PUMP ASSEMBLY
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Information injection-pump assembly

BOSCH 9 400 618 986 9400618986
ZEXEL 107692-0660 1076920660
NISSAN-DIESEL 1671395267 1671395267

Service parts 107692-0660 INJECTION-PUMP ASSEMBLY:

1. _
2. FUEL INJECTION PUMP 107069-1200
3. GOVERNOR 105921-6520
4. SUPPLY PUMP 105237-6140
5. AUTOM. ADVANCE MECHANIS
6. COUPLING PLATE 105663-0660
7. COUPLING PLATE 156638-3020
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:

107692-0660 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 986 9400618986
ZEXEL 107692-0660 1076920660
NISSAN-DIESEL 1671395267 1671395267


Zexel num
Bosch num
Firm num
Name
107692-0660 
9 400 618 986 
1671395267  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

Test data 107692-0660
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

Test data 107692-0660
F:Full speed I:Idle (1)Stopper bolt setting (2)-
----------

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

Stop lever angle

Test data 107692-0660
N:Pump normal S:Stop the pump. (1)- (2)Set the stopper bolt at speed = aa and rack position = bb and confirm non-injection.
----------
aa=1400r/min bb=5-0.5mm
----------
a=20deg+-5deg b=37deg+-5deg

0000001301

Test data 107692-0660
(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

Test data 107692-0660
(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

Test data 107692-0660
A : Stopper pin B: Connector
----------

----------

0000001801

Test data 107692-0660
C:Shim
----------

----------

0000001901

Test data 107692-0660
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 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
----------

0000002301 RACK SENSOR

Test data 107692-0660
(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 SPEED SENSOR

Test data 107692-0660
(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
----------

0000002501 BCS

Test data 107692-0660
(A) Boost pressure inlet (B) Screw for rack position adjustment (C): boost compensator spring (D): spring setting adjusting notch (E): Push rod 1. Instructions for adjusting the boost compensator (1)Select a pushrod to obtain dimension L at full boost. (2)(B) Adjust the boost compensator stroke with the screw. (3)(D) Move the adjusting nut to adjust the start of boost compensator operation.
----------
L=24+-0.5mm
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