101482-9291 ZEXEL 9 400 610 523 BOSCH INJECTION-PUMP ASSEMBLY 9400610523 1014829291 1679090376

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 523 9400610523

ZEXEL 101482-9291 1014829291

NISSAN-DIESEL 1679090376 1679090376

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Service parts 101482-9291 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101048-8150

3. GOVERNOR 105419-1412

4. SUPPLY PUMP 105220-5740

5. AUTOM. ADVANCE MECHANIS

6. COUPLING PLATE

7. COUPLING PLATE 156638-6020

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-6440

11. Nozzle and Holder 16600-90104

12. Open Pre:MPa(Kqf/cm2) 18.1{185}

13. NOZZLE-HOLDER 105048-3840

14. NOZZLE

105017-0900

15. NOZZLE SET

Include in #1:

101482-9291 as INJECTION-PUMP ASSEMBLY

106672-9990 as _

Cross reference number

BOSCH 9 400 610 523 9400610523

ZEXEL 101482-9291 1014829291

NISSAN-DIESEL 1679090376 1679090376

Zexel num

Bosch num

Firm num

Name

101482-9291

9 400 610 523

1679090376 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
BD30 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

Overflow valve 131424-1520

Overflow valve opening pressure kPa 157 123 191

Overflow valve opening pressure kgf/cm2 1.6 1.25 1.95

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 3.2 3.15 3.25

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 10.4

Pump speed r/min 1075 1075 1075

Average injection quantity mm3/st. 45.4 44.4 46.4

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.2+-0.5

Pump speed r/min 450 450 450

Average injection quantity mm3/st. 8 6 10

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 -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 62 62 72

Fixing the lever *

Rack limit *

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)Main spring setting (5)Set idle sub-spring (6)Rack difference from N = N1
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K=10 N1=1075r/min
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Speed control lever angle

F:Full speed I:Idle S:Stop (1)Set the stopper bolt at delivery (2)Confirmation
----------

----------
a=15deg+-5deg b=6deg+-5deg c=26deg+-5deg

Stop lever angle

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

----------
a=56.5deg+-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
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L=7.7mm
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a1=A a2=B a3=C a4=- r1=- r2=1075r/min r3=- r4=- Q1=- Q2=45.4+-1mm3/st Q3=- Q4=- c1=- c2=+-3.5% c3=- c4=- a5=23 a6=- a7=18 a8=- a9=- a10=- a11=- a12=- a13=- a14=- a15=- r5=1165r/min r6=1105r/min r7=900r/min r8=- r9=- r10=- r11=- r12=- r13=- r14=- r15=- R5=1245+-25r/min R6=1185+-25r/min R7=965+-25r/min R8=- R9=- R10=- R11=- R12=- R13=- R14=- R15=-

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'ZZ' at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(100deg)

Information:

Water Pump
Inspection of Water Pump
If the inspection of the impeller and shaft finds abnormal noise or rough rotation, replace the assembly.
Inspection of impeller and shaft rotation conditionThermostat
Disassembly of Thermostat
Inspection of Thermostat
To test the thermostat operation, immerse the thermostat in a container filled with water, and heat the water while measuring the water temperature. Record the temperature at which the valve starts to open and the temperature at which the valve lift becomes 8 mm [0.3 in.] or more. (a) Stir the water in the container to ensure uniform temperature distribution.(b) When installing the thermostat, be sure to check the valve opening temperature indication stamped on the upper face of the thermostat mounting flange.
Inspection of thermostatOverheat Warning Unit (Thermo Switch)
Inspection of Overheat Warning Unit
Immerse the temperature sensor in oil, and measure the resistance while increasing the oil temperature. If the temperature measurement exceeds the standard value significantly, replace the thermo switch.
Since the inspection requires heating of oil to high temperatures, be careful not to get burns or start a fire.
Overheat warning unit