101491-9260 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1014919260 1671290115

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101491-9260 1014919260

NISSAN-DIESEL 1671290115 1671290115

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Service parts 101491-9260 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101049-9210

3. GOVERNOR 105400-3920

4. SUPPLY PUMP 105220-4840

5. AUTOM. ADVANCE MECHANIS 105622-1440

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-6370

11. Nozzle and Holder 16600T9303

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105031-4600

14. NOZZLE

15. NOZZLE SET

Include in #1:

101491-9260 as INJECTION-PUMP ASSEMBLY

101602-3841 as _

Cross reference number

ZEXEL 101491-9260 1014919260

NISSAN-DIESEL 1671290115 1671290115

Zexel num

Bosch num

Firm num

Name

101491-9260
101491-9500

1671290115 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD33 * 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

Overflow valve 131424-6120

Overflow valve opening pressure kPa 191 157 225

Overflow valve opening pressure kgf/cm2 1.95 1.6 2.3

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 3.4 3.35 3.45

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 11.4

Pump speed r/min 1500 1500 1500

Average injection quantity mm3/st. 57.5 56.5 58.5

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 9.5+-0.5

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 10 8 12

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1500

Advance angle deg. 1.75 1.25 2.25

Timer adjustment_04

Pump speed r/min 1800

Advance angle deg. 3.5 3 4

Timer adjustment_05

Pump speed r/min -

Advance angle deg. 4 3.5 4.5

Remarks
Measure the actual speed, stop

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Target notch: K (2)Idle sub spring setting: L1. (3)Rack difference between N = N1 and N = N2
----------
K=11 L1=7-0.5mm N1=1500r/min N2=400r/min
----------

Speed control lever angle

F:Full speed I:Idle (1)Set the pump speed at aa. ( At delivery ) (2)Stopper bolt setting (3)Set the pump speed at bb.
----------
aa=1800r/min bb=1500r/min
----------
a=24deg+-5deg b=34deg+-5deg c=9deg+-5deg

Stop lever angle

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

----------
a=26.5deg+-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:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)-
----------

----------
a1=A a2=- r1=1500r/min r2=- Q1=57.5+-1mm3/st Q2=- c1=+-3.5% c2=- a3=36 a4=30 r3=1800r/min r4=1500r/min

Timing setting

(1)Pump vertical direction (2)Position of gear's standard threaded hole (position of gear mark 'N') at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=15deg
----------
a=(60deg)

Information:

1. Disconnect two Fuel lines (1).2. Remove four bolts (2) and remove fuel transfer pump and gasket. The following steps are for the installation of the fuel transfer pump.3. Position the gasket and fuel transfer pump then install bolts (2).4. Connect fuel lines (1).5. Prime the fuel system. See the MAINTENANCE MANUAL.Disassemble Fuel Transfer Pump
Start By:a. remove fuel transfer pump 1. Remove cover (1) from the fuel transfer pump. 2. Remove strainer (2). 3. Remove valve housing (3) from body (4). 4. Use a pencil grinder to remove the staked metal that holds inlet check valve (6) and outlet check valve (5) in place. Remove check valves (5) and (6). 5. Push the center of the diaphragm down and turn it 90° to disengage the actuator rod from the actuator arm. Remove diaphragm (7). 6. Remove spring (8). 7. Remove retainer (9). 8. Remove lever (12), shaft (11) and arm (10) as an assembly. 9. If necessary, remove washers (13) from shaft (11). Remove shaft (11) and separate arm (10) from lever (12). 10. If necessary, remove primer (14) and spring.11. Thoroughly inspect all parts of the fuel transfer pump. A repair kit is available to rebuild the fuel transfer pump. The following steps are for the assembly of the fuel transfer pump. 12. Install primer (14) and the spring on to body (4). 13. Install lever (12) into arm (10) and install pin (11) through the arm and lever. Put washer (13) on each side of arm (10). 14. Put spring (15) into position on the boss in body (4). Install arm (10) and lever (12) as an assembly into body (4). Be sure spring (15) engages with the tang on lever (12). 15. Install two retainers (9) to hold shaft (11) and arm and lever assembly in body (4). 16. Install spring (8) into body (4). 17. Install diaphragm (7) into body (4). Put the flat on the actuator rod in alignment with lever (12). Push the center of the diaphragm down and turn it 90° to engage the actuator rod with the actuator arm. 18. Install a gasket and check valve (6) and gasket and check valve (5) in valve body (3). Stake valve body (3) around each check valve to hold them in position. Make the stake marks at a different location than the original stake marks. 19. Put the valve body in place on diaphragm (7) and install the screws that hold it. 20. Put strainer (2) in position on valve body (3). 21. Install a new gasket in cover (1) and Install cover (1) on body.End By:a. install fuel transfer pump