106871-5180 ZEXEL 9 400 612 508 BOSCH INJECTION-PUMP ASSEMBLY 9400612508 1068715180 1671397815

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 508 9400612508

ZEXEL 106871-5180 1068715180

NISSAN-DIESEL 1671397815 1671397815

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Service parts 106871-5180 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 106080-5312

3. GOVERNOR 105487-6330

4. SUPPLY PUMP 105237-6020

5. AUTOM. ADVANCE MECHANIS 105681-1160

6. COUPLING PLATE 105663-0570

7. COUPLING PLATE

8. _

9. _

10. NOZZLE AND HOLDER ASSY 105100-7720

11. Nozzle and Holder 16600-97071

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/21.6{220}

13. NOZZLE-HOLDER 105030-4190

14. NOZZLE

105015-7890

15. NOZZLE SET

Include in #1:

106871-5180 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 508 9400612508

ZEXEL 106871-5180 1068715180

NISSAN-DIESEL 1671397815 1671397815

Zexel num

Bosch num

Firm num

Name

106871-5180

9 400 612 508

1671397815 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RF8 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 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 10

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 129.3 128.3 130.3

Max. variation between cylinders % 0 -4 4

Basic *

Fixing the lever *

Injection quantity adjustment_02

Adjusting point C

Rack position 6.4+-0.5

Pump speed r/min 235 235 235

Average injection quantity mm3/st. 10.4 8.4 12.4

Max. variation between cylinders % 0 -10 10

Fixing the rack *

Injection quantity adjustment_03

Adjusting point D

Rack position -

Pump speed r/min 100 100 100

Average injection quantity mm3/st. 140 120 160

Fixing the lever *

Remarks
After startup boost setting

Timer adjustment

Pump speed r/min 1000

Advance angle deg. 1.9 1.4 2.4

Timer adjustment_02

Pump speed r/min 1100

Advance angle deg. 5 4.5 5.5

Remarks
Finish

Test data Ex:

Governor adjustment

N:Pump speed R:Rack position (mm) (1)Tolerance for racks not indicated: +-0.05mm. (2)Torque control spring setting (3)Excess fuel setting for starting: SXL (N = N1) (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
----------
SXL=10.1+-0.1mm N1=450r/min
----------

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=13.5deg+-5deg b=5deg+-5deg

0000000901

F:Full load I:Idle (1)Stopper bolt setting (2)Use the hole at R = aa
----------
aa=64.3mm
----------
a=18.5deg+-5deg b=24.5deg+-3deg

Stop lever angle

N:Pump normal S:Stop the pump. (1)Drive side
----------

----------
a=12deg+-5deg b=64deg+-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:

Illustration 4 g01781374
Illustration 5 g01781397
Relocate the ether canister to the other side. Refer to Illustration 4 and Illustration 5.
Illustration 6 g01781413
(4) 322-7177 Bracket As (15) 8T-4121 Hard Washer (17) 8T-4196 Bolt
Install 322-7177 Bracket As (4) in the same location as the former muffler support bracket (30) by using four 8T-4121 Hard Washers (15), and four 8T-4196 Bolts (17). Refer to Illustration 3 and Illustration 6.
Illustration 7 g01781434
(6) 322-7180 Bracket As (8) 324-1454 Bracket Adapter (10) 5P-4116 Hard Washer (12) 6V-3822 Bolt (15) 8T-4121 Hard Washer (18) 8T-6870 Bolt
Install 322-7180 Bracket As (6) by using two 8T-4121 Hard Washers (15), and two 6V-3822 Bolts (12) to the exhaust elbow mounting holes. Place 324-1454 Bracket Adapter (8) between bracket assembly (6) and the aftercooler core assembly. Secure bracket assembly (6) to bracket adapter (8), and to the aftercooler core assembly by using two 5P-4116 Hard Washers (10), and two 8T-6870 Bolts (18). Refer to Illustration 7.
Illustration 8 g01781454
(5) 322-7179 Plate (15) 8T-4121 Hard Washer (16) 8T-4133 Nut (17) 8T-4196 Bolt
Install 322-7179 Plate (5) on top of bracket assembly (4), and bracket assembly (6). Secure plate (5) loosely using eight 8T-4121 Hard Washers (15), four 8T-4196 Bolts (17), four 8T-4133 Nuts (16). Refer to Illustration 8.
Illustration 9 g01781475
(2) 253-4495 Clamp As
Install two 253-4495 Clamp As (2) on top of plate (5). Use eight hard washers (15), four bolts (17), and four nuts (16). Secure the brackets loosely so that you are able to make adjustments. Refer to Illustration 9.
Illustration 10 g01781478
(c) Inlet tube (7) 322-9842 Diesel Particulate Filter Gp
Install 322-9842 Diesel Particulate Filter Gp (7) on top of the two bottom clamp assemblies (2). Insert inlet tube (c) on top of the exhaust elbow. The weight of the diesel particulate filter group is approximately 60 kg (132 lb). Refer to Illustration 10.
Illustration 11 g01781493
Cut off material from the bracket that originally supported the ether canister (if needed), to fit the diesel particulate filter group. Refer to Illustration 11.
Make sure that the filter is properly placed on top of clamp assemblies (2) and the exhaust elbow. If needed, adjust plate (5), and bracket assemblies (4) and (6). Once diesel particulate filter group (7) is properly positioned, tighten the bolts between the plate and the two bracket assemblies. Also, tighten the bolts of the bottom clamp assemblies (2) .
Illustration 12 g01781513
(d) Outlet tube (1) 7E-3870 Muffler Clamp (3) 277-4718 Clamp As (9) 3B-4508 Lockwasher (11) 5P-8245 Hard Washer (13) 6V-3823 Bolt (14) 6V-8149 Nut
Secure inlet tube (c) of the diesel particulate filter group to the exhaust elbow with one 7E-3870 Muffler Clamp (1). Refer to Illustration 12.
Position one 277-4718 Clamp As (3) over the diesel particulate filter group, and secure the clamp assembly to the bottom clamp assembly (2)