101441-9490 ZEXEL 9 400 610 077 BOSCH INJECTION-PUMP ASSEMBLY 9400610077 1014419490 1670025g01

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 077 9400610077

ZEXEL 101441-9490 1014419490

NISSAN-DIESEL 1670025G01 1670025g01

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Service parts 101441-9490 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101044-8100

3. GOVERNOR 105542-4401

4. SUPPLY PUMP

105220-5001

5. AUTOM. ADVANCE MECHANIS 105622-1060

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-2130

11. Nozzle and Holder 16600-36W00

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

13. NOZZLE-HOLDER 105071-1271

14. NOZZLE

105000-1740

15. NOZZLE SET

Include in #1:

101441-9490 as INJECTION-PUMP ASSEMBLY

Include in #2:

105866-5160 as _

Cross reference number

BOSCH 9 400 610 077 9400610077

ZEXEL 101441-9490 1014419490

NISSAN-DIESEL 1670025G01 1670025g01

Zexel num

Bosch num

Firm num

Name

101441-9490

9 400 610 077

1670025G01 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD23 * 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 2.15 2.1 2.2

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 -

Rack position 12

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 38.8 37.8 39.8

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.2+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8 6.9 9.1

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 1200

Advance angle deg. 2 1.5 2.5

Timer adjustment_04

Pump speed r/min 2150

Advance angle deg. 7 6.5 7.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) P:Negative pressure (1)Pneumatic governor (2)Mechanical governor (3)Acting negative pressure: P1 (4)RACK LIMIT: RAL (5)Beginning of idle sub spring operation: L1 (6)Without stopper disk (7)Injection quantity Q = Q1 or less (at N = N1)
----------
P1=2.94+-0.2kPa(300+-20mmAq) RAL=14.7-0.3mm L1=8.5+0.3mm Q1=3mm3/st N1=(2600)r/min
----------

Speed control lever angle

B:When boosted N:Normal S:Stop (1)Rack position = aa (2)Rack position corresponding to cc
----------
aa=0mm bb=15mm
----------
a=0deg+-5deg b=23deg+-3deg c=6deg+-5deg

0000001501 ACS

(N): Speed of the pump (P): governor's negative pressure (Pa): aneroid compensator's negative pressure (A) rubber boot (B) Nut (c) Nut (D) Lever 1. Aneroid compensator installation (1)Turn nut (C) to adjust gap to L1. (Remove rubber boot at adjustment.) (2)Lock using nut (B). (3)After installation, the lever D must move smoothly when the lever D is moved to the excess fuel side, and R = R1 or more.
----------
L1=0.1~0.5mm R1=16mm
----------
N=1000r/min P=0.5kPa(50mmAq) Ra=12mm Rb=- Rc=(11.6)mm Pa1=8-5.3kPa(60-40mmHg) Pa2=16.7kPa(125mmHg) Q1=- Q2=35.9+-1cm3/1000st

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=18deg
----------
a=(140deg)

Information:

Problem 4
The starting motor remains engaged or the starting motor continues to run after the engine is running.
Check the components of the starting circuit.
Measure the voltages at terminal (TS-26) of the junction box while the engine is running.Result
The voltage at the terminal is zero volts.The problem is in the starting motor (SM), the pinion solenoid (PS), or the magnetic switch (MS). Repair the faulty component. STOP.
The voltage at the terminal is between 15 volts and 32 volts.The START terminals of the start/stop switch are normally closed. This is normal for an automatic start system. In a manual start system, the switches should be normally open. The switch is on terminals (SSS-1) and (SSS-2) for a normal start/stop switch. Repair the faulty switch. STOP.Problem 5
The engine shutdown occurs after the engine runs for more than 3 minutes.
Check the protection switches.
Remove the jumper that is between terminals (TS-9) and (TS-10) of the junction box.
If the engine is equipped with a low oil pressure indicator, disconnect the diode that is between terminals (TS-8) and (TS-10). The cathode lead of the diode should be connected to terminal (TS-10).
If the engine is equipped with a low oil pressure indicator, ensure that a jumper is not installed between terminals (TS-8) and (TS-9).
Start the engine.
Reconnect the jumper that is between terminals (TS-9) and (TS-10) of the junction box after the test is completed.Result
The engine starts and the engine runs.The problem is in the oil pressure switch or the water temperature contactor switch. Go to Step 5 of "Problem 1".
The engine starts but engine shutdown occurs immediately.Go to Step 1 of "Problem 3".
The engine starts and the engine runs but engine shutdown occurs after the engine runs for more than 3 minutes.Go to Step 2.
The engine cranks but the engine does not start.Go to Step 1 of "Problem 1".
Check the start/stop switch and slave relay (SR1).
Disconnect the wire in the junction box that connects terminal (SR1-85) of the slave relay (SR1) to terminal (TD-7) of the time delay relay (TD).
Crank the engine. Activate the emergency stop switch, if necessary.Result
The engine starts and the engine runs.The start/stop switch has a short circuit or a wiring problem is causing a voltage at terminal (TD-7). Reconnect the wire to the terminal. STOP.
Engine shutdown still occurs after several minutes.The contacts of (SR1) periodically close. The problem may also be with the governor or the fuel supply to the engine. Refer to the Engine Service Manual. If a 2301A Electric Governor is used, the SR1 contacts may be opening. Refer to 2301A Electric Governor Service Manual, SENR3585. Test SR1. Refer to Testing and Adjusting, "Slave Relay Test".Problem 6
Engine shutdown does not occur when a fault is detected.
Check the protection switches and the crank terminate switch of the electronic speed switch.
Reset circuit breaker (CB7).
Start the engine and run the engine at low idle.
Contact with electrical components can cause injury or death.Remove all jewelry and avoid contact with electrical components. Use properly insulated tools when working on the junction box of an