106871-0564 ZEXEL 9 400 618 032 BOSCH INJECTION-PUMP ASSEMBLY 9400618032 1068710564 1671397674

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 032 9400618032

ZEXEL 106871-0564 1068710564

NISSAN-DIESEL 1671397674 1671397674

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Service parts 106871-0564 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7300

3. GOVERNOR 105487-3132

4. SUPPLY PUMP

105237-4180

5. AUTOM. ADVANCE MECHANIS 105636-2790

6. COUPLING PLATE 105662-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7270

11. Nozzle and Holder 1660097066

12. Open Pre:MPa(Kqf/cm2) 14.7(150)/19.6(200)

13. NOZZLE-HOLDER 105031-4790

14. NOZZLE

105015-6930

15. NOZZLE SET

Include in #1:

106871-0564 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 032 9400618032

ZEXEL 106871-0564 1068710564

NISSAN-DIESEL 1671397674 1671397674

Zexel num

Bosch num

Firm num

Name

106871-0564

9 400 618 032

1671397674 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 157 157 157

Overflow valve opening pressure kgf/cm2 1.6 1.6 1.6

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 9.3

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 106.5 105.5 107.5

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 8.6+-0.5

Pump speed r/min 1200 1200 1200

Average injection quantity mm3/st. 105.6 103.6 107.6

Max. variation between cylinders % 0 -4 4

Fixing the lever *

Injection quantity adjustment_03

Adjusting point F

Rack position 6+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11.5 9.5 13.5

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)Lever ratio: RT (2)Target shim dimension: TH (3)Tolerance for racks not indicated: +-0.05mm. (4)Rack limit using the stop lever: R1 (5)Excess fuel setting for starting: SXL (6)The torque control spring must does not have a set force. (7)Damper spring setting
----------
RT=1 TH=2.2mm R1=13.8+0.2mm SXL=10.1+-0.1mm
----------

Speed control lever angle

F:Full speed
----------

----------
a=0deg+-5deg

0000000901

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

----------
a=24.5deg+-5deg b=25.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side (2)Rack position = aa (3)Use the hole at R = bb
----------
aa=13.8+0.2mm bb=32mm
----------
a=36deg+-5deg b=10.5deg+-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
This Special Instruction provides detailed instructions on the installation of the sleeve into the compensator group of the 3408E and 3412E Unit Injector Hydraulic Pump. If leaks are experienced at the joint of the compensator and the adapter block, the 174-8943 Sleeve may be installed to improve sealing. The new press fit sleeve contains the O-ring more securely than the original slip fit sleeve.Note: Engines built prior to the serial number break that contain the new sleeve have a "S" stamped at the end of the part number on the serial number plate of the pump. The reworked part numbers appear as "144-0835-06S". Individual Components
Table 1
Quantity Part Number Part Description
1 174-8943 Sleeve
1 135-2652 O-Ring
1 033-6039 O-Ring
6 9X-7680 O-Ring Necessary Tools
One of the following tools may be used to insert the new sleeve into the compensator group.
A 31.750 mm (1.250 inch) diameter flat plate.
The 1P-0467 Drive Plate from 1P-0510 Driver Group .
An acceptable bearing insertion tool.Removal Of The O-Ring Seals
Illustration 1 g00638376
Remove the four bolts (1) from the compensator (2). Remove the compensator and the adapter. Do not adjust the compensator. Refer to Special Instruction, REHS0192-03, step 3 of procedure for "Disassembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 2 g00638368
Remove the four O-ring seals (3) from the bottom side of the adapter. Refer to Special Instruction, REHS0192-03, step 4 of procedure for "Disassembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 3 g00638372
Remove the four O-ring seals (4) from the two housings. Refer to Special Instruction, REHS0192-03, step 5 of procedure for "Disassembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Remove the slip fit sleeve from the compensator housing.Installation Of The Sleeve
Illustration 4 g00637918
(1) Compensator assembly. (2) 174-8943 Sleeve .
Invert the compensator assembly (1). Hold the compensator assembly securely within a vise or a press table.
Start the sleeve (2) by hand into the compensator assembly (1) .Note: It is important that the groove on the outside diameter of the sleeve is oriented toward the O-ring in the joint. If this is not done, there will not be sufficient room to properly seal the O-ring.
Press the sleeve (2) flush with the surface of the compensator assembly (1) using the 1P-0467 Drive Plate or by using an acceptable bearing insertion tool.Installation Of The O-Ring Seals
Illustration 5 g00638368
Install the four O-ring seals (3) on the bottom side of the adapter. Refer to Special Instruction, REHS0192-03, step 16 of procedure for "Assembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 6 g00638372
Install the four O-rings (4) on the two housings. Refer to Special Instruction, REHS0192-03, step 17 of procedure for "Assembly of the 144-0835 Unit Injector Hydraulic Pump Group ".
Illustration 7 g00638376
Install the compensator assembly (2) and the adapter as a unit vertically so that the O-rings seals are not damaged. Tighten the four bolts (1) to the following torque.Torque for bolts ... 8 1 N