101601-9400 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016019400

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101601-9400 1016019400

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Cross reference number

ZEXEL 101601-9400 1016019400

Zexel num

Bosch num

Firm num

Name

101601-9400
101601-9401

NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FD6 *

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 132424-0620

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 1-4-2-6- 3-5

Pre-stroke mm 3 2.95 3.05

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5

Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5

Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5

Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5

Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5

Injection quantity adjustment

Adjusting point -

Rack position 11.5

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.7 53.1 56.3

Max. variation between cylinders % 0 -2 2

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point H

Rack position 9.5+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 8.2 6.4 10

Max. variation between cylinders % 0 -12 12

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.5)

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 54.7 53.7 55.7

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point I

Rack position 14.5+-0. 5

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 80 80 90

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min (1230)

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 1500

Advance angle deg. 4 3.5 4.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)RACK LIMIT
----------

----------

Speed control lever angle

F:Full speed I:Idle (1)Stopper bolt set position 'H'
----------

----------
a=26.5deg+-5deg b=42deg+-3deg

Stop lever angle

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

----------
a=20deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(30deg)

Information:

(1) 2N2878 Spring (governor): Put a force on spring of ... 28.9 N (6.5 lb)Then add more force to make spring shorter by ... 10.69 mm (.421 in)Total test force ... 46.7 0.44 N (10.50 .10 lb)Free length after test ... 59.4 1.0 mm (2.34 .04 in)Outside diameter ... 33.99 0.38 mm (1.338 .015 in)Color code (stripes) ... one brown(2) 2W2216 Spring (broken link): Length under test force ... 26.33 mm (1.033 in)Test force ... 13.34 0.66 N (3.002 .149 lb)Free length after test ... 58.77 mm (2.313 in)Outside diameter ... 11.3 mm (.45 in)Color code (stripes) ... none(3) 4N6410 Spring (dashpot): Length under test force ... 26.16 mm (1.030 in)Test force ... 4.45 0.36 N (1.00 .08 lb)Free length after test ... 31.24 mm (1.230 in)Outside diameter ... 14.8 mm (.58 in)Color code (stripes) ... one pink(4) 3K5733 Spring (centering): Length under test force ... 19.3 mm (.76 in)Test force ... 61 5 N (13.7 1.1 lb)Free length after test ... 31.0 2.0 mm (1.22 .08 in)Outside diameter ... 14.35 mm (.565 in)Color code (stripes) ... none(5) Governor housing assembly.(6) 1W4243 Spring (bumper): Length under test force ... 26.3 mm (1.04 in)Test force ... 0.194 N (.0437 lb)Free length after test ... 32 mm (1.3 in)Outside diameter ... 8.3 mm (.33 in)Color code (stripes) ... one yellow(7) Full load stop block. (8) Distance four dowels extend above the surface of governor housing (5) ... 6.0 0.5 mm (.24 .02 in)(9) Distance two dowels extend above the surface of the governor housing ... 3.0 0.5 mm (.12 .02 in) (10) Distance from the surface of block (7) to the end of the dowel ... 62.00 0.75 mm (2.44 .03 in) (11) Tighten the plug to a torque of ... 11 2 N m (8.1 1.5 lb ft)(12) Tighten the body to a torque of ... 6.25 1.35 N m (4.6 1.0 lb ft)(13) Tighten the insulator to a torque of ... 3.4 0.5 N m (31 4 lb in)(14) Tighten bolts to a torque of ... 3.5 0.4 N m (2.57 4 lb in)