106871-0292 ZEXEL 9 400 618 015 BOSCH INJECTION-PUMP ASSEMBLY 9400618015 1068710292 1671397615

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 015 9400618015

ZEXEL 106871-0292 1068710292

NISSAN-DIESEL 1671397615 1671397615

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Service parts 106871-0292 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7530

3. GOVERNOR 105487-2230

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 105100-7140

11. Nozzle and Holder

12. Open Pre:MPa(Kqf/cm2) 14.7(150)/21.6(220)

13. NOZZLE-HOLDER 105031-4790

14. NOZZLE

105015-5450

15. NOZZLE SET

Include in #1:

106871-0292 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 015 9400618015

ZEXEL 106871-0292 1068710292

NISSAN-DIESEL 1671397615 1671397615

Zexel num

Bosch num

Firm num

Name

106871-0292

9 400 618 015

1671397615 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RE8 * K

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 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 1-8-7-5- 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 9.9

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 105.5 104.5 106.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point -

Rack position 5.6+-0.5

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 16 14 18

Max. variation between cylinders % 0 -10 10

Fixing the rack *

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

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)Variable speed specification. (2)Tolerance for racks not indicated: +-0.05mm. (3)Rack limit using stop lever: R1 (at N = N1) (4)Main spring setting (5)Set idle sub-spring (6)Damper spring setting
----------
R1=13.5+0.2mm N1=100r/min
----------

Speed control lever angle

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

----------
a=13.5deg+-5deg b=26deg+-5deg

0000000901

F:Full load (1)Fix the lever at the full load position
----------

----------
a=5deg+-5deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Rack position bb
----------
aa=13.5+0.2mm bb=1+0.5mm
----------
a=9.5deg+-5deg b=35deg+-3deg

0000001501 GOV FULL LOAD ADJUSTMENT

Title1:Full load stopper adjustment Title2:Governor set speed LABEL1:Distinguishing LABEL2:Pump speed (r/min) LABEL3:Ave. injection quantity (mm3/st) LABEL4:Max. var. bet. cyl. LABEL5:Remarks LABEL6:Distinguishing LABEL7:Governor set speed (r/min) LABEL8:Maximum no-load speed (r/min) LABEL9:Remarks (1)Adjustment conditions are the same as those for measuring injection quantity. (2)At high idle rack position L
----------
L=4.3mm
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a1=A a2=- a3=- a4=- r1=700r/min r2=- r3=- r4=- Q1=- Q2=105.5+-1mm3/st Q3=- Q4=- c1=+-4% c2=- c3=- c4=- a5=A-24 a6=A-23 a7=A-22 a8=A-21 a9=A-20 a10=A-19 a11=A-18 a12=- a13=- a14=- a15=- r5=1200r/min r6=1150r/min r7=1100r/min r8=1050r/min r9=1000r/min r10=950r/min r11=900r/min r12=- r13=- r14=- r15=- R5=1290+-30r/min R6=1235+-28r/min R7=1180+-27r/min R8=1130+-26r/min R9=1075+-25r/min R10=1020+-23r/min R11=965+-22r/min R12=- R13=- R14=- R15=-

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:

(1) 7S7144 Spring for valves (new): Length under test force ... 44.86 mm (1.766 in)Test force ... 257 25 N (57.7 4.5 lb)Length of spring at valve open position ... 32.28 mm (1.271 in)Load at minimum operating length ... 708 35 N (160 8 lb)Free length after test ... 52.07 mm (2.05 in)Outside diameter ... 35.21 mm (1.386 in)Spring must not be bent more than ... 1.82 mm (.072 in)(2) Height to top of valve guide ... 22.23 0.25 mm (.875 .010 in)(3) Diameter of valve stem (new) ... 9.441 0.008 mm (.3717 .0003 in) Use again minimum diameter ... 9.408 mm (.3704 in)Bore in valve guide with guide installed in the head.Minimum permissible (new) ... 9.456 mm (.3723 in)Maximum permissible (worn) ... 9.581 mm (.3772 in)(4) Valve lip thickness: 6N9916 Exhaust Valve Use again minimum ... 2.69 mm (.106 in)2W2620 Intake Valve Use again minimum ... 2.69 mm (.106 in)6N9915 Intake Valve Use again minimum ... 2.44 mm (.096 in)(5) Diameter of valve head: Exhaust valve ... 48.16 0.13 mm (1.896 .005 in)Intake valve ... 51.31 0.13 mm (2.020 .005 in)(6) Angle of valve face ... 29 1/4 1/4° (7) Depth of bore in head for valve seat insert ... 12.28 0.13 mm (.483 .005 in)(8) Diameter of valve seat insert for exhaust valve ... 50.889 0.013 mm (2.0035 .0005 in) Bore in head for valve seat insert for exhaust valve ... 50.813 0.030 mm (2.0005 .0012 in)Diameter of valve seat insert for intake valve ... 52.032 0.013 mm (2.0485 .0005 in)Bore in head for valve seat insert for intake valve ... 51.956 0.030 mm (2.0455 .0012 in)(9) Angle of face of valve seat insert ... 30 1°(10) Maximum permissible width of valve seat (intake and exhaust) ... 1.93 mm (.076 in) Minimum permissible width of valve seat (intake and exhaust) ... 1.14 mm (.045 in)(11) Dimension from top of closed valve to face of head: Minimum permissible dimension for 6N9916 Exhaust Valve ... 0.66 mm (.026 in)Minimum permissible dimension for 6N9915 or 2W2620 Intake Valve ... 0.15 mm (.006 in)(12) Outside diameter of the face of the valve seat insert: Exhaust seat ... 46.02 mm (1.812 in)Maximum permissible, exhaust seat ... 47.29 mm (1.862 in)Intake seat ... 49.28 mm (1.940 in)Maximum permissible, intake seat ... 50.55 mm (1.990 in)(13) Angle to grind seat face of the insert to get a reduction of maximum seat diameter ... 15°