101441-9310 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014419310 1679090177

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101441-9310 1014419310

NISSAN-DIESEL 1679090177 1679090177

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Service parts 101441-9310 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101044-8080

3. GOVERNOR 105410-7160

4. SUPPLY PUMP 105220-4630

5. AUTOM. ADVANCE MECHANIS 105622-0910

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 9.8(100)

13. NOZZLE-HOLDER 105071-1241

14. NOZZLE

105000-1010

15. NOZZLE SET

Include in #1:

101441-9310 as INJECTION-PUMP ASSEMBLY

Include in #2:

105856-7301 as _

Cross reference number

ZEXEL 101441-9310 1014419310

NISSAN-DIESEL 1679090177 1679090177

Zexel num

Bosch num

Firm num

Name

101441-9310

1679090177 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD25 * 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 6-2-600

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 1-3-4-2

Pre-stroke mm 2.3 2.25 2.35

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5

Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5

Injection quantity adjustment

Adjusting point A

Rack position 9.6

Pump speed r/min 1550 1550 1550

Average injection quantity mm3/st. 38.3 37.3 39.3

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 6.8+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8.2 7.1 9.3

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 900

Advance angle deg. 1.8 1.3 2.3

Timer adjustment_04

Pump speed r/min 1200

Advance angle deg. 3.3 2.8 3.8

Timer adjustment_05

Pump speed r/min 1500

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K
----------
K=8
----------

Speed control lever angle

I:Idle S:Stop (1)When pump speed set at aa (2)When speed set at bb (at shipping).
----------
aa=1900r/min bb=1650r/min
----------
a=29deg+-5deg b=20deg+-5deg c=32deg+-3deg d=29deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump.
----------

----------
a=19deg+-5deg b=53deg+-5deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=5mm
----------
a1=A a2=B a3=C a4=D a5=- a6=- r1=1550r/min r2=- r3=1150r/min r4=- r5=- r6=- Q1=41.5+-1mm3/st Q2=- Q3=38.3+-1mm3/st Q4=- Q5=- Q6=- c1=+-2.5% c2=- c3=+-2.5% c4=- c5=- c6=- a7=38 a8=37 a9=36 a10=35 a11=34 a12=33 a13=32 a14=31 a15=30 a16=29 a17=28 a18=27 a19=26 a20=25 a21=- a22=- a23=- a24=- a25=- a26=- a27=- a28=- r7=1900r/min r8=1850r/min r9=1800r/min r10=1750r/min r11=1700r/min r12=1650r/min r13=1600r/min r14=1550r/min r15=1500r/min r16=1450r/min r17=1400r/min r18=1350r/min r19=1300r/min r20=1250r/min r21=- r22=- r23=- r24=- r25=- r26=- r27=- r28=- R7=2040+-47r/min R8=1985+-46r/min R9=1935+-45r/min R10=1880+-43r/min R11=1825+-42r/min R12=1770+-41r/min R13=1720+-40r/min R14=1665+-38r/min R15=1610+-37r/min R16=1550+-36r/min R17=1505+-35r/min R18=1450+-33r/min R19=1395+-32r/min R20=1340+-31r/min R21=- R22=- R23=- R24=- R25=- R26=- R27=- R28=-

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(130deg)

Information:

Illustration 31 g00295348
(11) Rotating Group. (15) Shaft.
Install the rotating group (11) .
Position the housing so that the internal end of the shaft (15) is angled downward.
Slide the rotating group (11) over the shaft (15) and into the housing. Ensure that the shoes of the rotating group (11) are seated against the yoke.
Illustration 32 g00295349
(34) Pins
Once the rotating group is installed, turn the rotating group in order to ensure that the three pins (34) are still in the special notches. If the rotating group jams, the pins (34) need to be reinserted into the proper position. The three pins in the rotating group are held in the special notches with a "C" clip retaining ring. The "C" clip applies force against the inside diameter of the rotating group's cylinder block in order to hold the pins in position. See Illustration 32.
Illustration 33 g00295352
(7) Valve Block. (9) Housing Gasket. (35) Large Middle Hole.
Install the housing gasket (9) .
Moderately oil the face of the valve block (7) with clean engine oil. Place the control piston onto the control shaft.
Install the valve block (7) .
Place a finger over the large middle hole (35) in the mounting surface of the valve block (7) in order to create a vacuum. This will hold the control piston in place while you are installing the valve block (7) .
Ensure that the housing gasket (9) is not damaged while you are aligning the valve block (7) to the pins in the pump housing.
Illustration 34 g00295353
(7) Valve Block. (8) Bolts.
Start the bolts (8) in the valve block (7) by hand.
Torque the bolts (8) by alternating from all four sides. Torque the bolts (8) in the corners first. Tighten the bolts (8) to a torque of 27 2 N m (20 1 lb ft).
Illustration 35 g00295295
(5) O-Ring Seals. (6) O-Ring Seals.
Install the four O-Ring seals (5) on the bottom side of the adapter.
Install the four O-Ring seals (6) on the two housings.
Illustration 36 g00295294
(3) Compensator. (4) Bolts.
Install the compensator (3) and the adapter as a unit vertically so that the O-Ring seals are not damaged. Tighten the bolts (4) to a torque of 7.45 .65 N m (65.94 5.75 lb in).
Moderately oil the shaft seal.
Illustration 37 g00295354
(25) Shaft Seal. (36) FT-2608 Bearing Installation Tool .Note: Step 20 through Step 22 defines the procedure for the installation of the shaft seal. These steps should be followed precisely. The shaft seal should be placed barely below the face of the housing. The snap ring should then be positioned against the seal. Both the snap ring and the seal should be driven into the bore together until the snap ring seats in the groove.
Use the FT-2608 Bearing Installation Tool (36) to lower the shaft seal (25) below the edge of the bore.
Place the snap ring against the shaft seal below the edge of the bore.
Illustration 38 g00295356
(25) Shaft Seal. (26) Snap Ring. (36) FT-2608 Bearing Installation Tool .
Use the FT-2608 Bearing Installation Tool (36) in order to lower the shaft seal (25)