101691-9830 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1016919830 1671395105

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 101691-9830 1016919830

NISSAN-DIESEL 1671395105 1671395105

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Cross reference number

ZEXEL 101691-9830 1016919830

NISSAN-DIESEL 1671395105 1671395105

Zexel num

Bosch num

Firm num

Name

101691-9830

1671395105 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
NE6T *

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 3.7 3.65 3.75

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 1400 1400 1400

Average injection quantity mm3/st. 109 107.4 110.6

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 -

Rack position 9.8+-0.5

Pump speed r/min 275 275 275

Average injection quantity mm3/st. 9 7.2 10.8

Max. variation between cylinders % 0 -10 10

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 1400 1400 1400

Average injection quantity mm3/st. 109 108 110

Basic *

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_04

Adjusting point B

Rack position R1-0.1

Pump speed r/min 900 900 900

Average injection quantity mm3/st. 101.4 99.4 103.4

Fixing the lever *

Boost pressure kPa 30.7 30.7

Boost pressure mmHg 230 230

Injection quantity adjustment_05

Adjusting point C

Rack position R2(12.6)

Pump speed r/min 400 400 400

Average injection quantity mm3/st. 61.6 59.6 63.6

Fixing the lever *

Boost pressure kPa 0 0 0

Boost pressure mmHg 0 0 0

Injection quantity adjustment_06

Adjusting point I

Rack position -

Pump speed r/min 150 150 150

Average injection quantity mm3/st. 85 85 105

Fixing the lever *

Rack limit *

Boost compensator adjustment

Pump speed r/min 600 600 600

Rack position R3(12)

Boost pressure kPa 4 2.7 5.3

Boost pressure mmHg 30 20 40

Boost compensator adjustment_02

Pump speed r/min 600 600 600

Rack position R3+0.4

Boost pressure kPa 9.3 8 10.6

Boost pressure mmHg 70 60 80

Boost compensator adjustment_03

Pump speed r/min 600 600 600

Rack position R1-0.6

Boost pressure kPa 17.3 17.3 17.3

Boost pressure mmHg 130 130 130

Timer adjustment

Pump speed r/min 920--

Advance angle deg. 0 0 0

Remarks
Start

Timer adjustment_02

Pump speed r/min 870

Advance angle deg. 0.5

Timer adjustment_03

Pump speed r/min 1400

Advance angle deg. 2 1.5 2.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Torque cam stamping: T1 (2)RACK LIMIT (3)Boost compensator stroke: BCL
----------
T1=B36 BCL=(1.1)+-0.1mm
----------

Speed control lever angle

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

----------
a=26.5deg+-5deg b=43deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Use the hole at R = aa
----------
aa=36mm
----------
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=(40deg)

Information:

You must read and understand the warnings and instructions contained in the Safety section of this manual before performing any operation or maintenance procedures.Before proceeding with this maintenance interval, perform previous maintenance intervals and Daily maintenance requirements. Perform the maintenance at the interval listed in the Maintenance Schedule for your engine.
For maintenance of the following components in this interval, refer to the OEM manual for maintenance instructions. The following are basic suggestions and instructions.
Marine Gear
Drain Oil
With the oil warm and the engine stopped, drain the transmission.1. Remove the transmission drain plug and allow the oil to drain. Obtain an oil sample for analysis.2. Clean and install the drain plug.If a Sump Pump is Used to Drain Oil
a. Connect a drain line and container to top outlet (A) of pump.b. Be sure valve (B) on the engine oil pan line is closed. Marks on the valve must be turned at right angles to the direction of the engine oil line. c. Open valve (C) on the transmission oil line. The marks on this valve must be turned so that one mark points to the pump and the second mark points to the transmission.d. Operate the sump pump (D) handle until the transmission is empty.e. Close the sump pump valve on the oil line to the transmission.Change Filters
1. Remove transmission oil filter housing drain plug (if equipped). Allow the oil to drain into the marine gear transmission sump.2. Remove filter assembly. Disassemble and discard the element.3. Clean the filter housing and assembly parts with clean, nonflammable solvent. Clean and install the filter housing drain plug.4. Inspect any retainer plates and/or seals. Install new seals if necessary.5. Assemble and install a new filter element assembly. Tighten all bolts.6. Operate the sump pump handle until the transmission is empty. Close the sump pump valve on the oil line to the transmission.Clean the Oil Strainer
1. Remove the strainer cover and plug. Remove the spring washer, strainer screen and magnetic screen tube (if equipped).2. Wash the strainer and magnetic screen tube with clean, nonflammable solvent. If a magnet is broken, install the new magnet properly. The North (N) poles and South (S) poles of the magnets are adjacent to each other so that they repel instead of attract: S-N, N-S, S-N.3. Inspect the strainer, plug and the cover seal for damage. Use new parts if used ones are damaged.4. Install the magnetic screen tube, strainer, spring washer, seal, cover and plug.Clean the Breather (All Marine Transmissions)
1. Remove the breather.2. Clean the breather with clean, nonflammable solvent.3. Install the breather.Fill the Transmission
Be sure both sump pump valves (one to the transmission and one to the engine oil pan) are closed. Otherwise a transfer of oil may occur during sump pump operation and damage could result.
1. Be sure the marine gear drain plug has been installed, or the sump pump valve (C) on the oil line to the marine gear drain line has been closed.2. Fill the marine gear to the FULL mark on the