101631-9761 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016319761

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101631-9761 1016319761

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Service parts 101631-9761 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 101063-9380

3. GOVERNOR 105542-4230

4. SUPPLY PUMP 105220-4871

5. AUTOM. ADVANCE MECHANIS 105622-1100

6. COUPLING PLATE

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105141-1881

11. Nozzle and Holder 16600-20053

12. Open Pre:MPa(Kqf/cm2) 9.8{100}

13. NOZZLE-HOLDER 105071-1241

14. NOZZLE

105000-1080

15. NOZZLE SET

Include in #1:

101631-9761 as INJECTION-PUMP ASSEMBLY

Include in #2:

104740-3280 as _

Cross reference number

ZEXEL 101631-9761 1016319761

Zexel num

Bosch num

Firm num

Name

101631-9761
101631-9763

NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD33 *

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

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 2.15 2.1 2.2

Rack position R=11.7

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 12.2

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 32.1 31.1 33.1

Max. variation between cylinders % 0 -2.5 2.5

Basic *

Fixing the rack *

Injection quantity adjustment_02

Adjusting point -

Rack position 11.7

Pump speed r/min 1900 1900 1900

Average injection quantity mm3/st. 36.1 34.5 37.7

Max. variation between cylinders % 0 -4 4

Fixing the rack *

Injection quantity adjustment_03

Adjusting point -

Rack position 8.6+-0.5

Pump speed r/min 300 300 300

Average injection quantity mm3/st. 7.5 6.5 8.5

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Injection quantity adjustment_04

Adjusting point -

Rack position -

Pump speed r/min 800 800 800

Average injection quantity mm3/st. 32.1 31.6 32.6

Remarks
Set full load.

Timer adjustment

Pump speed r/min 550--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 500

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 1.7 1.2 2.2

Timer adjustment_04

Pump speed r/min 1900

Advance angle deg. 6 5.5 6.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) P:Negative pressure (1)Pneumatic governor (2)Mechanical governor (3)Acting negative pressure: P1 (4)RACK LIMIT: RAL (5)Beginning of idle sub spring operation: L1 (6)With stopper disk. (7)Injection quantity Q = Q1 or less
----------
P1=3.63+-0.2kPa(370+-20mmAq) RAL=17-0.3mm L1=9+0.3mm Q1=3mm3/st
----------

Speed control lever angle

N:Normal B:When boosted S:Stop (1)Rack position = aa
----------
aa=(1.8)mm
----------
a=20.5deg+-3deg b=8deg+-5deg c=0.5deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of gear mark 'Y' at No 1 cylinder's beginning of injection (3)B.T.D.C.: aa (4)-
----------
aa=20deg
----------
a=(130deg)

Information:

Start By:a. remove exhaust manifoldb. remove inlet manifoldc. remove fuel injection nozzle assembliesd. remove fuel filtere. remove water temperature regulatorf. remove cylinder head assembly 1. Put cylinder head assembly (1) in position on tool group (A). 2. Put compression on valve spring (2) with tool (C). 3. Remove spring locks (3). 4. Remove tool (C). Remove valve spring cap (2) and valve springs (4). 5. Remove washer (5) and O-ring seal (8) from valve (7).6. Remove seal (6). Remove valve (7). 7. Check the valve spring tension with tool (B). The outer spring force must be 180 9 N (40 2 lb.). The length of the spring under test force must be 27.4 mm (1.08 in.). The free length after test must be 45.2 mm (1.78 in.). The inner spring force must be 68.5 9 N (15.4 2 lb.). The length of the spring under test force must be 23.88 mm (.940 in.). The length after test must be 39.6 mm (1.56 in.).8. Do Steps 1 through 8 again for the remainder of the valves. If the cylinder head is equipped with removable valve guides, refer to module SENB8082-06, System Operating Testing And Adjusting Specifications, 4.236 And 4.2482 Diesel Engines For Lift Trucks.Install Valves
1. Put clean engine oil on the valve stems.2. Install valve (3), washer (2) and seal (1).
The closed coil of the spring must be toward the cylinder head.
3. Install springs (5) and valve spring cap (4). 4. Use tool (A), and put springs under compression, and install O-ring seal on the valve. Exhaust valves have an extra O-ring seal on them.
Locks (6) can be thrown from the valve when tool (A) is released if they are not in their correct position on the valve stem.
5. Use tool (B), and install locks (6) that hold the springs in place.6. Remove tool (A), and hit the top of the valve with a plastic hammer to be sure the locks are in their correct position on the valve.7. Do Steps 1 through 6 again for the remainder of the valves.End By:a. install cylinder head assemblyb. install water temperature regulatorc. install fuel filterd. install fuel injection nozzle assembliese. install inlet manifold