101441-9651 ZEXEL 9 400 614 140 BOSCH INJECTION-PUMP ASSEMBLY 9400614140 1014419651 1679090379

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 614 140 9400614140

ZEXEL 101441-9651 1014419651

NISSAN-DIESEL 1679090379 1679090379

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Service parts 101441-9651 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101044-8290

3. GOVERNOR 105410-9821

4. SUPPLY PUMP 105220-4950

5. AUTOM. ADVANCE MECHANIS 105622-1650

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105148-1121

11. Nozzle and Holder

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

13. NOZZLE-HOLDER 105078-0050

14. NOZZLE

105007-1130

15. NOZZLE SET

Include in #1:

101441-9651 as INJECTION-PUMP ASSEMBLY

Include in #2:

105856-1644 as _

Cross reference number

BOSCH 9 400 614 140 9400614140

ZEXEL 101441-9651 1014419651

NISSAN-DIESEL 1679090379 1679090379

Zexel num

Bosch num

Firm num

Name

101441-9651

9 400 614 140

1679090379 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
TD2304 * K 14BC INJECTION PUMP ASSY PE4A,5A, PE

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 11.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 38.6 37.6 39.6

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 8.1+-0.5

Pump speed r/min 350 350 350

Average injection quantity mm3/st. 8 6.9 9.1

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Remarks
Adjust only variation between cylinders; adjust governor according to governor specifications.

Injection quantity adjustment_03

Adjusting point D

Rack position 14.7-0.3

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 52 42 62

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 3 2.5 3.5

Timer adjustment_03

Pump speed r/min 1800

Advance angle deg. 4.5 4 5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT: RAL (4)Set idle sub-spring (5)Main spring setting (6)Rack difference between N = N1 and N = N2
----------
K=8 RAL=14.7-0.3mm N1=1600r/min N2=1000r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt setting
----------

----------
a=34deg+-5deg b=26deg+-5deg

Stop lever angle

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

----------
a=12deg+-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=6.2mm
----------
a1=A a2=B a3=C a4=- a5=- a6=- r1=1000r/min r2=1000r/min r3=1000r/min r4=- r5=- r6=- Q1=- Q2=38.6+-1mm3/st Q3=- Q4= Q5= Q6= c1=+-4% c2=+-4% c3=+-4% c4=- c5=- c6=- a7=36 a8=35 a9=34 a10=33 a11=32 a12=31 a13=30 a14=29 a15=28 a16=27 a17=26 a18=25 a19=24 a20=23 a21=22 a22=21 a23=20 a24=19 a25=- a26=- a27=- a28=- r7=1800r/min r8=1750r/min r9=1700r/min r10=1650r/min r11=1600r/min r12=1550r/min r13=1500r/min r14=1450r/min r15=1400r/min r16=1350r/min r17=1300r/min r18=1250r/min r19=1200r/min r20=1150r/min r21=1100r/min r22=1050r/min r23=1000r/min r24=950r/min r25=- r26=- r27=- r28=- R7=1935+-45r/min R8=1880+-43r/min R9=1825+-42r/min R10=1770+-41r/min R11=1720+-40r/min R12=1665+-38r/min R13=1610+-37r/min R14=1555+-36r/min R15=1505+-35r/min R16=1450+-33r/min R17=1395+-32r/min R18=1340+-31r/min R19=1290+-30r/min R20=1235+-28r/min R21=1180+-27r/min R22=1130+-26r/min R23=1075+-25r/min R24=1020+-23r/min R25=- R26=- R27=- R28=-

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=18deg
----------
a=(100deg)

Information:

Table 1
Conversion Table
Current Hertz RPM
4.0 0 0
4.5 159 38
5.0 319 75
5.5 478 113
6.0 638 150
6.5 797 188
7.0 956 225
7.5 1116 263
8.0 1275 300
8.5 1434 338
9.0 1594 375
9.5 1753 413
10.0 1913 450
10.5 2072 488
11.0 2231 525
11.5 2391 563
12.0 2550 600
12.5 2709 638
13.0 2869 675
13.5 3028 713
14.0 3188 750
14.5 3347 788
15.0 3506 825
15.5 3666 863
16.0 3825 900
16.5 3984 938
17.0 4144 975
17.5 4303 1013
18.0 4463 1050
18.5 4622 1088
19.0 4781 1125
19.5 4941 1163
20.0 5100 1200
Illustration 5 g00562935
Calibrate the transmitter.
Disconnect the wiring from the transmitter.
Ensure that the resistor is located on the input side of the transmitter. The resistor should be across the positive terminal and the negative terminal.
Connect an ammeter and a signal generator as you are shown in illustration 5.
Ensure that the signal generator is not generating a signal (zero Hertz).
Adjust the zero dial until the ammeter reads 4 mA.
Adjust the signal generator in order to produce an output of 5100 HZ.
Adjust the span dial until the ammeter reads 20 mA.
Adjust the signal generator in order to produce an output of zero hertz. Verify that the ammeter reads 4 mA.
The ammeter reads 4 mA. STOP.
The ammeter does not read 4 mA. Proceed to 3.
Readjust the frequency input.
Adjust the signal generator in order to produce zero Hertz.
Adjust the zero dial until the ammeter reads 4 mA.
Adjust the signal generator in order to produce an output of 5100 HZ.
Adjust the span dial until the ammeter reads 20 mA.
Adjust the signal generator in order to produce an output of zero hertz. Verify that the ammeter reads 4 mA.Note: Repeat the procedure in order to calibrate a frequency transmitter properly. Continue until both the 4 mA and the 20 mA readings are correct.
The ammeter reads 4 mA and 20 mA at the desired input frequency. STOP.
The ammeter does not read 4 mA and 20 mA. Replace the transmitter. Verify that this repair eliminates the problem.Magnetic Pickup Sensor
The magnetic pickup sensor sends the engine speed signal to the engine speed switch and to the transmitter.
Illustration 6 g00562936
Setting and Adjustment
Adjust the sensor's clearance from the flywheel.
The engine is secured. Install the sensor until the sensor contacts the flywheel.
Back off the sensor (1.2 0.1 turns).
Measure clearance between the flywheel and the