101641-9210 ZEXEL 9 400 610 026 BOSCH INJECTION-PUMP ASSEMBLY 9400610026 1016419210

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 610 026 9400610026

ZEXEL 101641-9210 1016419210

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104749-3140 as _

Cross reference number

BOSCH 9 400 610 026 9400610026

ZEXEL 101641-9210 1016419210

Zexel num

Bosch num

Firm num

Name

101641-9210
101641-9214

9 400 610 026

NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
SD33T *

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 2.3 2.25 2.35

Rack position
Point A R=A

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 13.7

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 48.3 47.2 49.4

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 -

Rack position 9.9+-0.5

Pump speed r/min 360 360 360

Average injection quantity mm3/st. 7.5 6.4 8.6

Max. variation between cylinders % 0 -15 15

Fixing the rack *

Standard for adjustment of the maximum variation between cylinders *

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

Injection quantity adjustment_03

Adjusting point A

Rack position R1(13.7)

Pump speed r/min 1000 1000 1000

Average injection quantity mm3/st. 48.3 47.2 49.4

Basic *

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.7

Pump speed r/min 2000 2000 2000

Average injection quantity mm3/st. 47.2 45.2 49.2

Fixing the lever *

Boost pressure kPa 53.3 53.3

Boost pressure mmHg 400 400

Injection quantity adjustment_05

Adjusting point C

Rack position R2(12.7)

Pump speed r/min 500 500 500

Average injection quantity mm3/st. 34.6 32.6 36.6

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Boost compensator adjustment

Pump speed r/min 700 700 700

Rack position R2(12.7)

Boost pressure kPa 15.3 12.6 18

Boost pressure mmHg 115 95 135

Boost compensator adjustment_02

Pump speed r/min 700 700 700

Rack position R1(13.7)

Boost pressure kPa 46.7 40 46.7

Boost pressure mmHg 350 300 350

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 1200

Advance angle deg. 2.2 1.7 2.7

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) (1)Torque cam stamping: T1 (2)Boost compensator stroke: BCL
----------
T1=74 BCL=1+-0.1mm
----------

Speed control lever angle

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

----------
a=37deg+-5deg b=43deg+-3deg

Stop lever angle

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

----------
a=10deg+-5deg b=40deg+-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:

Reassembly and adjustment (2-spring nozzle)
Adjust while assembling the parts by the following procedures.As the prelift is adjusted in 1/100 mm increments, use clean detergent to thoroughly remove dust and dirt before adjustment.The following special tools are necessary for adjustment. Adjusting Steps
(1) Adjustment of nozzle opening pressure(2) Selection of prelift adjusting shims(3) Adjustment of 2-spring adjusting pressure(4) * Check of needle valve full lift(5) Installation of prelift shims(6) * Checking of prelift(7) * Checking of 2-spring adjusting pressure(8) InspectionInspection make operations marked with * as necessary for inspection or confirmation.(1) Adjustment of nozzle valve opening pressure (a) Using the special tool, Retasining Nut for Adjustment, install the nozzle and needle valve to the nozzle holder. 1. Make sure that the knock pin has seated completely in the nozzle before tightening the retaining nut for adjustment. Tighten the retaining nut finger tight and then tighten to specified torque using a torque wrench.2. Remove the bolt from the tip of the retaining nut. (b) Insert 1st push rod 1st spring, valve opening pressure adjusting shim (first use about 1 mm thick one) and spacer to the nozzle holder. Then tighten the setscrew to specified torque. (c) Install the nozzle holder to the special tool, Nozzle Tester and adjust the shim thickness for nominal injection pressureShim types 0.50, 0.52, 0.54, 0.56, 0.58 0.60, 0.70, 0.80, 0.90, 1.00, 0.10, 0.20, 0.30, 0.40 mm 1. When using a shim, be sure to check its thickness by a micrometer.2. Use same shim for prelift adjustment.3. Use of a 0.02 mm thick shim changes the valve opening pressure by about 235 kPa (2.4 kgf/cm2)(2) Selection of prelift adjusting shim(a) 0 point adjustment of Adjusting Device Install the special tool, Dial Gauge to the special tool, Adjusting Device.Install the 2nd push rod to the special tool, Base and install the assembly to a vice.Set the pin and Adjusting Device as indicated in the above illustration and adjust 0 point of the Dial Gauge Use a 60.5 mm long pin.(b) Install the 2nd push rod to the nozzle holder. Do not install the 2nd spring and prelift adjusting shim. (c) Install the Adjusting Device to the setscrew using its intermediate screw.After installation, holding the Dial Gauge at its holder, move it up and down to check that the gauge operates smoothly.Push down the gauge, holding its holder and read its lift h. Read to 1/100 mm(d) Selection of prelift adjusting shim (e) Remove the Adjusting Device from the Nozzle Holder.(3) Adjustment of 2-spring adjusting pressure Install the 2nd spring, adjusting screw and lock nut to the nozzle holder. Do not install the prelift adjusting shim. Using the special tool, Nozzle Tester, adjust the adjusting screw for nominal injection pressure.After adjustment, tighten the lock nut to specified torque.(4) Checking full lift of needle valve (a) Install the special tools indicated in above illustration and set 0 point of the Dial Gauge.(b) Install the nozzle to the Nozzle Tester and operate the tester lever to bleed the inside of