101441-9772 ZEXEL 9 400 611 499 BOSCH INJECTION-PUMP ASSEMBLY 9400611499 1014419772 1679090400

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 499 9400611499

ZEXEL 101441-9772 1014419772

NISSAN-DIESEL 1679090400 1679090400

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Service parts 101441-9772 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101044-8290

3. GOVERNOR 105419-1111

4. SUPPLY PUMP 105220-4950

5. AUTOM. ADVANCE MECHANIS 105622-1770

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105148-1120

11. Nozzle and Holder 16600-43G02

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

13. NOZZLE-HOLDER 105078-0050

14. NOZZLE

105007-1130

15. NOZZLE SET

Include in #1:

101441-9772 as INJECTION-PUMP ASSEMBLY

Include in #2:

105856-0370 as _

Cross reference number

BOSCH 9 400 611 499 9400611499

ZEXEL 101441-9772 1014419772

NISSAN-DIESEL 1679090400 1679090400

Zexel num

Bosch num

Firm num

Name

101441-9772

9 400 611 499

1679090400 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 900 900 900

Average injection quantity mm3/st. 37 36 38

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 7.8+-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 C

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 41 36 46

Fixing the lever *

Rack limit *

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 1300

Advance angle deg. 2.6 2.1 3.1

Timer adjustment_04

Pump speed r/min -

Advance angle deg. 4.7 4.7 4.7

Remarks
Measure the actual speed, stop

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 (4)Rack difference between N = N1 and N = N2
----------
K=18 N1=1300r/min N2=900r/min
----------

Speed control lever angle

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

----------
a=28deg+-5deg b=18deg+-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=6.7mm
----------
a1=A a2=B a3=C a4=- a5=- a6=- r1=900r/min r2=900r/min r3=900r/min r4=- r5=- r6=- Q1=- Q2=37+-1mm3/st Q3=- Q4=- Q5=- Q6=- c1=+-4% c2=+-4% c3=+-4% c4=- c5=- c6=- a7=26 a8=25 a9=24 a10=23 a11=22 a12=21 a13=20 a14=19 a15=18 a16=17 a17=16 a18=15 a19=14 a20=- r7=1300r/min r8=1250r/min r9=1200r/min r10=1150r/min r11=1100r/min r12=1050r/min r13=1000r/min r14=950/min r15=900r/min r16=850r/min r17=800r/min r18=750r/min r19=700r/min r20=- R7=1395+-32r/min R8=1340+-31r/min R9=1290+-30r/min R10=1235+-28r/min R11=1180+-27r/min R12=1130+-26r/min R13=1075+-25r/min R14=1020+-23r/min R15=965+-22r/min R16=915+-22r/min R17=860+-20r/min R18=820+-18r/min R19=775+-17r/min R20=-

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:

API Degrees - Temperature Correction Chart for Diesel Fuel
Record the corrected API gravity from this chart.Table of Horsepower Correction Factors
Table 2
Corrected API
Gravity at 60° F Precombustion
Chamber Engines Direct Injection Engines (Use the correct full load RPM)
1800 2000 2200 2400 2600 2800 3000 3200
32.0
32.5
33.0
33.5
34.0 .984
.987
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995 .986
.988
.990
.992
.995
34.5
35.0
35.5
36.0
36.5 .997
1.000
1.003
1.005
1.008 .998
1.000
1.003
1.007
1.013 .998
1.000
1.003
1.007
1.010 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.007
1.011 .998
1.000
1.004
1.008
1.012 .998
1.000
1.004
1.008
1.012 .998
1.000
1.004
1.008
1.012
37.0
37.5
38.0
38.5
39.0 1.011
1.014
1.017
1.020
1.023 1.014
1.018
1.022
1.025
1.029 1.014
1.018
1.022
1.026
1.030 1.014
1.018
1.022
1.026
1.030 1.015
1.019
1.022
1.026
1.030 1.015
1.019
1.023
1.027
1.031 1.016
1.020
1.024
1.028
1.032 1.016
1.020
1.024
1.028
1.033 1.016
1.021
1.025
1.029
1.034
39.5
40.0
40.5
41.0
41.5 1.027
1.030
1.034
1.038
1.043 1.034
1.038
1.043
1.048
1.053 1.034
1.038
1.043
1.048
1.054 1.034
1.039
1.044
1.049
1.055 1.035
1.040
1.045
1.050
1.056 1.036
1.040
1.045
1.051
1.056 1.036
1.041
1.046
1.051
1.057 1.037
1.042
1.047
1.053
1.059 1.039
1.045
1.047
1.057
1.064
42.0
42.5
43.0
43.5
44.0 1.047
1.053
1.060
1.067
1.076 1.059
1.066
1.073
1.082
1.095 1.060
1.067
1.074
1.084
1.096 1.061
1.068
1.076
1.085
1.098 1.062
1.069
1.077
1.086
1.099 1.063
1.070
1.078
1.087
1.100 1.064
1.071
1.079
1.088
1.102 1.066
1.072
1.081
1.091
1.105 1.072
1.080
1.089
1.099
1.115 Use the above chart to find the horsepower correction factor.Calculating the Corrected Horsepower
Determine the rated full load horsepower from the Rack Setting Information Book.
Divide the rated horsepower by the horsepower correction factor for fuel density; the result is the corrected horsepower.Example:1674 - Truck Engine Serial No. 94B2551Rated Horsepower: 270 HorsepowerCalculations:
Table 3
1. Measured API gravity: 40.4' API at 50' (round to 40' API)
2. Corrected API gravity (see chart): 41' API at 60'F
3. Hpr correction factor (see chart): 1.038
4. Corrected Hp = Rated Hpr = 270 = 260 Hp
Correction Factor 1.038 (or 3.75% hp loss) Correcting for Fuel Density When Testing Engines on a Dynamometer
When engines are tested on a dynamometer which measures actual flywheel or drive train output, the observed horsepower is dependent on the fuel used. If the fuel being used is not 35° API at 60°F, then any dynamometer readings must be corrected to determine the output if 35° API fuel had been used. The same horsepower correction factor is used, but the formula is different:Corrected Horsepower = Observed Horsepower x Horsepower Correction FactorExample:1674 Truck Engine, Serial No. 9482551Rated (full load Horsepower: 270 Horsepower)Observed (dynamometer) Horsepower: 260 HorsepowerCalculations:
Measured API gravity: 39.6° API at 50°F (round to 40° API)
Corrected API Gravity (see chart): 41° API at 60°F
Horsepower Correction Factor (see chart): 1.038
Corrected Horsepower = Observed Horsepower x Horsepower Correction Factor 260 horsepower x 1.038 = 270 horsepower(Although the dynamometer indicated low horsepower, if the proper fuel had been used, the engine would be operating at rated output. The factory tolerance on rated engine output is 3%.)REFERENCE: For more information on dynamometer testing diesel engines, see Special Instruction Form GEG01024 .Diesel Fuel API Gravity to IbsJU.S. gallon or kg/liter Conversion Chart
The following chart may be used to convert the fuel API gravity to Ibs./U.S. gallon or kg/liter. These weights are for reference and are to be used when evaluating engine performance. Measurement of fuel flow rates can be converted