101603-9550 ZEXEL 9 400 615 300 BOSCH INJECTION-PUMP ASSEMBLY 9400615300 1016039550 16700z5700

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 615 300 9400615300

ZEXEL 101603-9550 1016039550

NISSAN-DIESEL 16700Z5700 16700z5700

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Service parts 101603-9550 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-3660

3. GOVERNOR 105462-7540

4. SUPPLY PUMP 105220-7050

5. AUTOM. ADVANCE MECHANIS 105614-3500

6. COUPLING PLATE 105661-0401

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105101-6340

11. Nozzle and Holder 16600-Z5600

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

13. NOZZLE-HOLDER 105031-4650

14. NOZZLE 105015-8750

15. NOZZLE SET

Include in #1:

101603-9550 as INJECTION-PUMP ASSEMBLY

Include in #2:

104741-5700 as _

Cross reference number

BOSCH 9 400 615 300 9400615300

ZEXEL 101603-9550 1016039550

NISSAN-DIESEL 16700Z5700 16700z5700

Zexel num

Bosch num

Firm num

Name

101603-9550

9 400 615 300

16700Z5700 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FE6A K 14BE INJECTION PUMP ASSY PE6A 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 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 A

Rack position 8.3

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 57.3 56.3 58.3

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.7+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 8.7 6.9 10.5

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 81 81

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min (1140)

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)Tolerance for racks not indicated: +-0.05mm. (2)Excess fuel setting for starting: SXL (3)Damper spring setting
----------
SXL=10.3+-0.1mm
----------

0000000901

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

----------
a=17deg+-5deg b=19.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the pin at R = aa (2)Rack position bb
----------
aa=20mm bb=(1.2)mm
----------
a=71deg+-5deg b=40deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of timer's threaded hole at No 1 cylinder's beginning of injection (3)- (4)-
----------

----------
a=(60deg)

Information:

Recommended Procedure With Chassis Dynamometer
Possible Causes/CorrectionsMinor Operating Faults
To help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the Primary Engine Checks section.Fuel Ratio Control Out Of Adjustment Or Bad
Follow the procedure in the Testing and Adjusting section of this Service Manual.Check Engine Performance
Do a Power Analysis Report (PAR), Level II, to check engine performance. See Special Instruction, Form No. SEHS8025 and SEHS7886 for the tooling and procedures to use. Be sure to make a record of the temperatures for inlet air, fuel (at filter base), lubricating oil and coolant. Make the necessary adjustments or repairs to the engine if needed.At this point, the governor fuel settings should be verified. See the Testing and Adjusting section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see Owner/Operator Input section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic.Recommended Procedure Without Chassis Dynamometer
Possible Causes/CorrectionsMinor Operating Faults
To help identify a problem before a more involved troubleshooting procedure is started, follow the procedure given in the Primary Engine Checks section.Fuel Ratio Control Out Of Adjustment Or Bad
Follow the procedure in the Testing and Adjusting section of this Service Manual.Fuel Injection Timing Not Correct
Follow the procedures in the Testing and Adjusting section of this Service Manual.Check Engine Performance
Install the tooling and follow the procedure given in the Road Test section.At this point, the governor fuel settings should be verified. See the Testing and Adjusting section of this Service Manual for the necessary procedures. Also, refer back to the information learned earlier (see Owner/Operator Input section) about the truck specifications and application and judge whether or not the engine is performing as expected or customer expectation is realistic.