106871-0125 ZEXEL 9 400 618 009 BOSCH INJECTION-PUMP ASSEMBLY 9400618009 1068710125 1671397575

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 009 9400618009

ZEXEL 106871-0125 1068710125

NISSAN-DIESEL 1671397575 1671397575

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Service parts 106871-0125 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7530

3. GOVERNOR 105487-0984

4. SUPPLY PUMP 105217-6040

5. AUTOM. ADVANCE MECHANIS 105636-2790

6. COUPLING PLATE 105662-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-5840

11. Nozzle and Holder 1660097019

12. Open Pre:MPa(Kqf/cm2) 19.6(200)

13. NOZZLE-HOLDER 105031-4210

14. NOZZLE

105015-5450

15. NOZZLE SET

Include in #1:

106871-0125 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 009 9400618009

ZEXEL 106871-0125 1068710125

NISSAN-DIESEL 1671397575 1671397575

Zexel num

Bosch num

Firm num

Name

106871-0125

9 400 618 009

1671397575 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RE8 K 14CD INJECTION PUMP ASSY PE8P PE

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 8-3-600

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 1-8-7-5- 4-3-6-2

Pre-stroke mm 3.65 3.6 3.7

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.5 45.5

Difference between angles 2
Cal 1-7 deg. 90 89.5 90.5

Difference between angles 3
Cal 1-5 deg. 135 134.5 135.5

Difference between angles 4
Cal 1-4 deg. 180 179.5 180.5

Difference between angles 5
Cal 1-3 deg. 225 224.5 225.5

Difference between angles 6
Cal 1-6 deg. 270 269.5 270.5

Difference between angles 7
Cyl.1-2 deg. 315 314.5 315.5

Injection quantity adjustment

Adjusting point A

Rack position 10.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 107.2 106.2 108.2

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 5.7+-0.5

Pump speed r/min 250 250 250

Average injection quantity mm3/st. 11.9 9.9 13.9

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Timer adjustment

Pump speed r/min 750

Advance angle deg. 0.5

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 1.4 0.9 1.9

Timer adjustment_03

Pump speed r/min 1150

Advance angle deg. 5.5 5 6

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Beginning of damper spring operation: DL (2)Rack limit using the stop lever: R1 (3)Damper spring setting (4)Variable speed specification: idling adjustment (5)Set idle sub-spring (6)Main spring setting
----------
DL=5.7-0.2mm R1=10.6+0.2mm
----------

Speed control lever angle

F:Full speed I:Idle
----------

----------
a=11deg+-5deg b=10deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting
----------

----------
a=24.5deg+-5deg b=33deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the hole at R = bb
----------
aa=10.6+0.2mm bb=32mm
----------
a=27.5deg+-5deg b=2deg+-5deg

Timing setting

(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)- (4)-
----------

----------
a=(90deg)

Information:

Introduction
1. Type 2 fuel injector. 2. Two piece follower. 3. Nose cone. 4. Nozzle assembly.Tools are now available for the removal and installation of nose cone (3), on type 2 fuel injectors (1), when it is necessary to replace a nozzle assembly (4). Type 2 fuel injectors can be identified by the two piece follower (2).
5. 1U9395 Plate. 6. 1U8701 Socket.Use 1U9395 Plate (5) with the 6V4830 Fixture Group (not shown) and the procedure given in this instruction, for the removal and installation of nozzle assembly (4).Earlier type 2 injectors have a nose cone that has serrations on its exterior. These serrations will be damaged when the nose cone is removed. A damaged nose cone is not to be used again. A 7C9795 Nose Cone is available for use as a replacement for the original nose cone.The 7C9795 Nose Cone has a hexagon shape on its exterior. This nose cone can be installed and tightened using 1U8701 Socket (6). When the 7C9795 Nose Cone is installed, be sure to tighten it according to the procedure given in this instruction.Removal and Installation of Nose Cone and Nozzle Assembly
1. Remove the original plate from the 6V4830 Fixture Group and install 1U9395 Plate (1).2. Put injector (2) in position on the fixture group. If the exterior of the injector nose cone is a hexagon shape as shown at location (A), use the 1U8701 Socket for nose cone removal. 3. If the exterior of the nose cone has serrations as shown at location (B), use a pipe wrench, as shown, to remove the nose cone. Anytime a pipe wrench is used to remove a nose cone, the nose cone will be damaged. Never use or install a damaged nose cone on an injector. Always install a new 7C9795 Nose Cone as a replacement. 4. After the nose cone has been loosened, use a hammer and 6V4822 Tip Driver (3) to tap the nozzle assembly as shown. This is done to break the connection between the nozzle assembly and the nose cone. Be sure to use only the 6V4822 Tip Driver in this procedure, because use of a standard punch, or any other similar tool will cause damage to the nozzle tip.5. Remove the nose cone and nozzle assembly. 6. Inspect surface (C) in the injector. This is the sealing surface for the nozzle assembly. This surface must be clean and free of any scratches, nicks or burrs. Even a piece of lint from a shop towel can cause a leak and destroy nozzle performance. 7. Remove original O-ring seal (4). Install a new O-ring seal, refer to the Parts Book for the correct part number. Make sure the O-ring seal is not damaged during installation.Use a generous amount of 1P0808 Grease, or a good grade of multi-purpose lubricant, to lubricate the O-ring seal before the nose cone is installed.8. Install new nozzle assembly (5) on the injector. 9. Install and finger tighten the new 7C9795 Nose Cone on the injector. Using a