101607-9780 ZEXEL 9 400 610 735 BOSCH INJECTION-PUMP ASSEMBLY 9400610735 1016079780 16713z6560

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 735 9400610735

ZEXEL 101607-9780 1016079780

NISSAN-DIESEL 16713Z6560 16713z6560

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Service parts 101607-9780 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101060-6190

3. GOVERNOR 105932-1940

4. SUPPLY PUMP 105220-7150

5. AUTOM. ADVANCE MECHANIS 105672-5260

6. COUPLING PLATE 105662-1470

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105118-7290

11. Nozzle and Holder 16600-Z6004

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/22.6{230}

13. NOZZLE-HOLDER 105048-4020

14. NOZZLE 105017-2160

15. NOZZLE SET

Include in #1:

101607-9780 as INJECTION-PUMP ASSEMBLY

Include in #2:

104746-5350 as _

Cross reference number

BOSCH 9 400 610 735 9400610735

ZEXEL 101607-9780 1016079780

NISSAN-DIESEL 16713Z6560 16713z6560

Zexel num

Bosch num

Firm num

Name

101607-9780
101607-9781

9 400 610 735

16713Z6560 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
MD92 * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8260

Bosch type code 9 430 610 133

Nozzle 105780-0120

Bosch type code 1 688 901 990

Nozzle holder 105780-2190

Opening pressure MPa 18

Opening pressure kgf/cm2 184

Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600

Overflow valve 131424-8921

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 255 255 255

Tester oil delivery pressure kgf/cm2 2.6 2.6 2.6

Direction of rotation (viewed from drive side)
Left L

Injection timing adjustment

Direction of rotation (viewed from drive side)
Left L

Injection order 1-4-2-6- 3-5

Pre-stroke mm 3.7 3.65 3.75

Beginning of injection position
Governor 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 11.8

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 95 93.4 96.6

Max. variation between cylinders % 0 -3.5 3.5

Basic *

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_02

Adjusting point Z

Rack position 9.5+-0.5

Pump speed r/min 280 280 280

Average injection quantity mm3/st. 12 11 13

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

Injection quantity adjustment_03

Adjusting point A

Rack position R1(11.8)

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 95 94 96

Basic *

Fixing the lever *

Injection quantity adjustment_04

Adjusting point B

Rack position R1+0.9

Pump speed r/min 1450 1450 1450

Average injection quantity mm3/st. 100.5 96.5 104.5

Fixing the lever *

Injection quantity adjustment_05

Adjusting point I

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 125 125 135

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 970--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 920

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min (1000)

Advance angle deg. 1.5 1 2

Timer adjustment_04

Pump speed r/min 1160

Advance angle deg. 1.5 1 2

Timer adjustment_05

Pump speed r/min 1450

Advance angle deg. 7 6.5 7.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)Tolerance for racks not indicated: +-0.05mm. (3)RACK LIMIT
----------
T1=L85
----------

Speed control lever angle

F:Full speed I:Idle (1)Use the hole at R = aa (2)Stopper bolt set position 'H'
----------
aa=38mm
----------
a=6.5deg+-5deg b=35deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa (2)No return spring
----------
aa=32mm
----------
a=10deg+-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=(80deg)

Information:

Locations and Methods for Measuring the Pressures of the Low-Pressure Fuel System
Illustration 1 g03325145
Front View of a typical fuel inlet lines group (A) Fuel inlet port (B) Test port for the fuel supply pressure (C) Fuel transfer pump (D) Test port location for system pressureInlet Fuel Pressure to the Transfer Pump (set at rated speed and load)
Install a 6V-3965 Fitting into Port (B) using a 214-7568 O-Ring Seal Note: The inlet pressure to the fuel transfer pump can affect overall system pressure. All filters or water separators before the transfer pump must be new and clean prior to setting the system pressure at the fuel pressure regulator.
Connect the 6V-7830 Pressure Gauge to the fitting installed in the previous step.
Set the engine to rated speed and load. Record the fuel pressure, and refer to the specifications above.Primary and Secondary Fuel Filter Differential Pressure
Primary and secondary fuel filter differential pressures are determined by the pressures from both sides of the fuel filters. This measurement will monitor fuel filter cleanliness and determine when the fuel filters require changing. Filter replacement will vary depending on fuel quality. Fuel quality can change with each shipment of fuel so monitoring the filter differential is necessary to obtain maximum filter life.Too high of a differential can cause air bubbles in the fuel system and if not corrected will lead to poor performance and injector damage. After the measurements are taken, refer to the specification above for the maximum allowable differential pressure.Primary filters or water separators should be properly sized to meet the flow requirements of the engine or engines as well as fuel being returned to the tank. Reference Table 4 for the flow requirements.
Table 4
3600 Engine Fuel Flow
Engine Model Rated Speed (rpm) Fuel Flow to Engine Fuel Flow from Engine Fuel Heat Rejection
3606 1000
41.5 L/min (11 US gpm)
32.4 L/min (8.6 US gpm)
12.5 kW (712 Btu/min)
900
38 L/min (10 US gpm)
30.0 L/min (7.9 US gpm)
11.0 kW (626 Btu/min)
750
31.5 L/min (8.3 US gpm)
24.5 L/min (6.5 US gpm)
10.5 kW (598 Btu/min)
720
30 L/min (7.9 US gpm)
23.6 L/min (6.2 US gpm)
10.0 kW (567 Btu/min)
3608 1000
41.5 L/min (11 US gpm)
30.0 L/min (7.9 US gpm)
16.7 kW (951 Btu/min)
900
38 L/min (10 US gpm)
27.6 L/min (7.3 US gpm)
14.6 kW (831 Btu/min)
750
31.5 L/min (8.3 US gpm)
22.6 L/min (6.0 US gpm)
14.0 kW (797 Btu/min)
720
30 L/min (7.9 US gpm)
21.4 L/min (5.6 US gpm)
13.3 kW (757 Btu/min)
3612 1000
78.5 L/min (20.7 US gpm)
60.1 L/min (15.9 US gpm)
25.0 kW (1423 Btu/min)
900
72 L/min (19 US gpm)
55.4 L/min (14.6 US gpm)
22.0 kW (1252 Btu/min)
750
61.2 L/min (16.2 US gpm)
47.3