106871-0642 ZEXEL 9 400 618 039 BOSCH INJECTION-PUMP ASSEMBLY 9400618039 1068710642 1671397702

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 618 039 9400618039

ZEXEL 106871-0642 1068710642

NISSAN-DIESEL 1671397702 1671397702

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Service parts 106871-0642 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106087-7480

3. GOVERNOR 105487-2503

4. SUPPLY PUMP

105237-4180

5. AUTOM. ADVANCE MECHANIS 105681-2220

6. COUPLING PLATE 105662-1150

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7700

11. Nozzle and Holder 1660097070

12. Open Pre:MPa(Kqf/cm2) 17.7(180)/19.6(200)

13. NOZZLE-HOLDER 105031-4790

14. NOZZLE

105015-6810

15. NOZZLE SET

Include in #1:

106871-0642 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 618 039 9400618039

ZEXEL 106871-0642 1068710642

NISSAN-DIESEL 1671397702 1671397702

Zexel num

Bosch num

Firm num

Name

106871-0642

9 400 618 039

1671397702 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RF8 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 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 650 650 650

Average injection quantity mm3/st. 129.4 128.4 130.4

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point B

Rack position 7+-0.5

Pump speed r/min 225 225 225

Average injection quantity mm3/st. 11 9 13

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point C

Rack position 12.4+0.2

Pump speed r/min 40 40 40

Average injection quantity mm3/st. 128 118 138

Fixing the lever *

Rack limit *

Timer adjustment

Pump speed r/min 950--

Advance angle deg. 0 0 0

Load 3/4

Remarks
Start

Timer adjustment_02

Pump speed r/min 900

Advance angle deg. 0.5

Load 3/4

Timer adjustment_03

Pump speed r/min 1100

Advance angle deg. 4 3.5 4.5

Load 4/4

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Rack limit using the stop lever: R1 (2)Excess fuel setting for starting: SXL (3)Damper spring setting: DL
----------
R1=12.4+0.2mm SXL=10.3+0.2mm DL=6.5-0.2mm
----------

Speed control lever angle

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

----------
a=1deg+-5deg

0000000901

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

----------
a=24.5deg+-5deg b=26deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Rack position = aa (2)Use the hole at R = bb
----------
aa=12.4+0.2mm bb=32mm
----------
a=32deg+-5deg b=3deg+-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:

3. Install dowel (5) in governor shaft (6). Install the governor shaft in the carrier as shown. 4. Put the carrier in position on the camshaft. Install the bolts that hold the carrier in place.
Replace shield (7) with a new part any time it is removed.
5. Install shield (7) on the carrier, and use Tool (A) to push the shield against its seat. Use a hammer and punch to stake the metal in two places on the side of the shield 180° 5° apart next to the holes in the shield. 6. Install one race (9), bearing (10), the other race (9), and use Tool (B) to install the ring on riser (8) as shown. 7. Install riser (8) and the spring (overfueling spring) on the governor shaft as shown. 8. Assemble the dashpot as follows:a. Install spring (12) on seat (11). Install seat (13) in spring (12).b. Put spool (14) and ring (15) in position on seat (13). Use Tool (B) to install snap ring (16) to hold them in place. 9. Install dashpot assembly (17) on the governor shaft as shown. 10. Install ring (21) in the lower groove in the governor shaft. Install one sleeve (20), spring (19), the other sleeve (20) and bearing (18) on the governor shaft as shown. Spring (19) is used to put a preload on the thrust bearing on the camshaft in the fuel injection pump housing.11. Use Tool (C) to hold spring (19) under compression. Install ring (22) in the groove in the governor shaft. Remove Tool (C). 12. Put lever (27) in position on governor servo (23). Install pin (24) to hold the lever in place. Use a hammer and chisel to stake the metal four places 90° apart on the outside surface on both legs of the governor servo to hold pin (24) in place.13. Install the O-ring seal on sleeve (25). Install piston (26) and sleeve (25) in the governor servo as shown. 14. Install valve (28) in the governor servo as shown. 15. Install one lockring (32) in the groove near the center of valve (28). Put sleeve (29), spring (broken link spring) (30) and seat (31) in position on valve (28). Install the other lockring (32) to hold the components in place. 16. Put the governor servo in position on the fuel injection pump housing with piston (26) engaged over rack (33). Install the bolts that hold the governor servo in place. The 3306 Engine has two adjustment screws and lock nuts.17. Install torque rise adjustment screw (36) in collar (34) as shown. Install locknut (35) on the screw. 18. Install bolt (38) in block (40) as shown. Install spring (37) on bolt (38) as shown. Put collar (34) in position on bolt (38) with the hole in the collar