108622-0060 ZEXEL 9 400 612 844 BOSCH INJECTION-PUMP ASSEMBLY 9400612844 1086220060 1671396916

Information Cross number Calibration Data Calibration Data Ex

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Information injection-pump assembly

BOSCH 9 400 612 844 9400612844

ZEXEL 108622-0060 1086220060

NISSAN-DIESEL 1671396916 1671396916

Service parts 108622-0060 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-3090

3. GOVERNOR 105923-0100

4. SUPPLY PUMP 105237-6030

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE 105664-2030

7. COUPLING PLATE

8. _ 159590-8020

9. _

10. NOZZLE AND HOLDER ASSY 105100-7151

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 18.6{190}/22.6{230}

13. NOZZLE-HOLDER 105030-4980

14. NOZZLE 105015-6580

15. NOZZLE SET

Include in #1:

108622-0060 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 844 9400612844

ZEXEL 108622-0060 1086220060

NISSAN-DIESEL 1671396916 1671396916

Zexel num

Bosch num

Firm num

Name

108622-0060
108622-0080

9 400 612 844

1671396916 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
D0XC * 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 134424-4120

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

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

Digi switch no. 21

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 6.4 6.37 6.43

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 15.8

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 200 197 203

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the rack *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

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 355 355 355

Average injection quantity mm3/st. 14.2 13.2 15.2

Max. variation between cylinders % 0 -10 10

Fixing the rack *

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Standard for adjustment of the maximum variation between cylinders *

Remarks
Refer to items regarding the pre-stroke actuator

Injection quantity adjustment_03

Adjusting point A

Rack position R1(15.8)

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 200 198 202

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.4

Pump speed r/min 1050 1050 1050

Average injection quantity mm3/st. 162.5 156.5 168.5

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_05

Adjusting point C

Rack position (R1-0.95 )

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 195 189 201

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_06

Adjusting point D

Rack position (R1-2.45 )

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 138 132 144

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Boost compensator adjustment

Pump speed r/min 250 250 250

Rack position R2-1.5

Boost pressure kPa 6.7 5.4 8

Boost pressure mmHg 50 40 60

Boost compensator adjustment_02

Pump speed r/min 250 250 250

Rack position R2(R1-1. 4)

Boost pressure kPa 40 40 40

Boost pressure mmHg 300 300 300

0000001601

Pre-stroke mm 6.4 6.37 6.43

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 8.5 8 9

Remarks
When the eccentric pin is tightened

_03

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 4 3.95 4.05

Output voltage V 2.45 2.44 2.46

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 6.4 6.37 6.43

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_05

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 3.4

Output voltage V 3 2.98 3

Confirmation *

_06

Supply voltage V 24 23.5 24.5

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=AA47 BCL=1.5+-0.1mm
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Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=39mm
----------
a=35deg+-3deg b=35deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)Set the stopper screw so that speed = bb, rack position = cc (after setting apply red paint).
----------
aa=40mm bb=0r/min cc=1.5+-0.3mm
----------
a=20deg+-5deg b=44deg+-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=6.4+-0.03mm
----------
a=(30deg)

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.
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0000002201 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)
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N1=600r/min Ra=R1(15.8)mm
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