Information injection-pump assembly
BOSCH
9 400 610 851
9400610851
ZEXEL
106671-5251
1066715251
NISSAN-DIESEL
1671396914
1671396914
Rating:
Service parts 106671-5251 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
16600-96603
12.
Open Pre:MPa(Kqf/cm2)
22.6{230}
15.
NOZZLE SET
Include in #1:
106671-5251
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 610 851
9400610851
ZEXEL
106671-5251
1066715251
NISSAN-DIESEL
1671396914
1671396914
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
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 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.9
3.85
3.95
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.5 60.5
Cal 1-4 deg. 60 59.5 60.5
Difference between angles 2
Cyl.1-2 deg. 120 119.5 120.5
Cyl.1-2 deg. 120 119.5 120.5
Difference between angles 3
Cal 1-6 deg. 180 179.5 180.5
Cal 1-6 deg. 180 179.5 180.5
Difference between angles 4
Cal 1-3 deg. 240 239.5 240.5
Cal 1-3 deg. 240 239.5 240.5
Difference between angles 5
Cal 1-5 deg. 300 299.5 300.5
Cal 1-5 deg. 300 299.5 300.5
Injection quantity adjustment
Adjusting point
A
Rack position
12.5
Pump speed
r/min
1050
1050
1050
Average injection quantity
mm3/st.
199
197
201
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the lever
*
Boost pressure
kPa
80
80
Boost pressure
mmHg
600
600
Injection quantity adjustment_02
Adjusting point
C
Rack position
6.4+-0.5
Pump speed
r/min
260
260
260
Average injection quantity
mm3/st.
13.5
12.2
14.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Injection quantity adjustment_03
Adjusting point
D
Rack position
8.8
Pump speed
r/min
400
400
400
Average injection quantity
mm3/st.
91.5
85.5
97.5
Fixing the lever
*
Boost pressure
kPa
0
0
0
Boost pressure
mmHg
0
0
0
Boost compensator adjustment
Pump speed
r/min
400
400
400
Rack position
8.8
Boost pressure
kPa
13.3
12
14.6
Boost pressure
mmHg
100
90
110
Boost compensator adjustment_02
Pump speed
r/min
400
400
400
Rack position
11.75
Boost pressure
kPa
50.7
44
57.4
Boost pressure
mmHg
380
330
430
Boost compensator adjustment_03
Pump speed
r/min
400
400
400
Rack position
12.7+0.2
Boost pressure
kPa
66.7
66.7
66.7
Boost pressure
mmHg
500
500
500
Timer adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
700
Advance angle
deg.
0.5
Timer adjustment_03
Pump speed
r/min
1050
Advance angle
deg.
1
0.5
1.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Tolerance for racks not indicated: +-0.05mm.
(2)Rack limit using the stop lever: R1
(3)Boost compensator stroke: BCL
(4)Damper spring setting
(5)Variable speed specification: idling adjustment
(6)Fix the lever at the full-load position at delivery.
(7)Main spring setting
(8)Perform governor adjustment at an ambient temperature of at least 15 deg C (boost compensator start spring is shape memory alloy).
----------
R1=12.7+0.2mm BCL=(4)mm
----------
----------
R1=12.7+0.2mm BCL=(4)mm
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Pump speed = aa
(2)Set the stopper bolt (fixed at full-load position at delivery.)
----------
aa=290r/min
----------
a=16deg+-5deg b=5deg+-5deg
----------
aa=290r/min
----------
a=16deg+-5deg b=5deg+-5deg
0000000901
F:Full load
I:Idle
(1)Stopper bolt setting
(2)Use the hole at R = aa
----------
aa=42mm
----------
a=32deg+-3deg b=45deg+-5deg
----------
aa=42mm
----------
a=32deg+-3deg b=45deg+-5deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
----------
aa=12.7+0.2mm
----------
a=41.5deg+-5deg b=40deg+-5deg
----------
aa=12.7+0.2mm
----------
a=41.5deg+-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=(20deg)
----------
----------
a=(20deg)
Information:
Start By:a. remove timing gear coverb. remove fuel injection pump housing and rack actuator package 1. Remove four bolts (2), plate (3) and idler gear (1). 2. If the camshaft is not going to be removed, use tooling (A) to remove camshaft gear (4).
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves, or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.4. Remove timing gear plate (6). 5. Use tooling (B) to remove the bearing from the idler gear. The following steps are for the installation of the timing gears and plate.6. Install a new gasket on the timing gear plate.7. Put timing gear plate (6) in position on the cylinder block, and install the bolts that hold the timing gear plate to the cylinder block.8. Heat camshaft gear (4) to a maximum temperature of 315° C (600° F), and install it on the camshaft.9. Use tooling (B), and install the bearing in the idler gear. Set the gear on the front face, (face with timing marks). Drive the bearing from the rear face toward the front face of the gear. Install the bearing to a depth of 1.5 0.5 mm (.06 .02 in.) below the rear face of the idler gear.10. Install the idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so "V" mark (7) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K" marks (8) of the camshaft gear can be seen at the outer edges of the idler gear.End By:a. install fuel injection pump housing and rack actuator packageb. install timing gear cover
Do not turn the crankshaft with the camshaft gear removed. Damage can be caused to the pistons and valves, or both.
3. Remove bolts (5) that hold timing gear plate (6) to the cylinder block.4. Remove timing gear plate (6). 5. Use tooling (B) to remove the bearing from the idler gear. The following steps are for the installation of the timing gears and plate.6. Install a new gasket on the timing gear plate.7. Put timing gear plate (6) in position on the cylinder block, and install the bolts that hold the timing gear plate to the cylinder block.8. Heat camshaft gear (4) to a maximum temperature of 315° C (600° F), and install it on the camshaft.9. Use tooling (B), and install the bearing in the idler gear. Set the gear on the front face, (face with timing marks). Drive the bearing from the rear face toward the front face of the gear. Install the bearing to a depth of 1.5 0.5 mm (.06 .02 in.) below the rear face of the idler gear.10. Install the idler gear, plate and bolts. Be sure No. 1 cylinder is at top center on the compression stroke. Install the idler gear so "V" mark (7) on the idler gear is in alignment with the "V" mark on the crankshaft gear. "K" marks (8) of the camshaft gear can be seen at the outer edges of the idler gear.End By:a. install fuel injection pump housing and rack actuator packageb. install timing gear cover