Information injection-pump assembly
BOSCH
9 400 616 194
9400616194
ZEXEL
101701-9470
1017019470
NISSAN-DIESEL
16801Z6000
16801z6000

Rating:
Service parts 101701-9470 INJECTION-PUMP ASSEMBLY:
1.
_
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
12.
Open Pre:MPa(Kqf/cm2)
14.7(150)/17.7(180)
14.
NOZZLE
Cross reference number
BOSCH
9 400 616 194
9400616194
ZEXEL
101701-9470
1017019470
NISSAN-DIESEL
16801Z6000
16801z6000
Zexel num
Bosch num
Firm num
Name
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8310
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2240
Opening pressure
MPa
18
Opening pressure
kgf/cm2
184
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
134424-4120
Overflow valve opening pressure
kPa
255
221
289
Overflow valve opening pressure
kgf/cm2
2.6
2.25
2.95
Tester oil delivery pressure
kPa
255
255
255
Tester oil delivery pressure
kgf/cm2
2.6
2.6
2.6
RED4 control unit part number
407915-0
590
RED4 rack sensor specifications
mm
19
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-4-2-6-
3-5
Pre-stroke
mm
3.5
3.47
3.53
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25
Cal 1-4 deg. 60 59.75 60.25
Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25
Cyl.1-2 deg. 120 119.75 120.25
Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25
Cal 1-6 deg. 180 179.75 180.25
Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25
Cal 1-3 deg. 240 239.75 240.25
Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25
Cal 1-5 deg. 300 299.75 300.25
Injection quantity adjustment
Rack position
(10.2)
PWM
%
45.7
Pump speed
r/min
700
700
700
Average injection quantity
mm3/st.
51.5
50.5
52.5
Max. variation between cylinders
%
0
-3.5
3.5
Basic
*
Injection quantity adjustment_02
Rack position
(7.6)
PWM
%
30.7+-2.
8
Pump speed
r/min
325
325
325
Average injection quantity
mm3/st.
13
12
14
Max. variation between cylinders
%
0
-8
8
Governor adjustment
Pump speed
r/min
900--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Governor adjustment_02
Pump speed
r/min
850
Advance angle
deg.
0.3
Governor adjustment_03
Pump speed
r/min
1270
Advance angle
deg.
4
3.7
4.3
Remarks
Finish
Finish
Test data Ex:
Speed control lever angle

N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=1mm bb=20mm
----------
a=38.5deg+-5deg b=37deg+-5deg
----------
aa=1mm bb=20mm
----------
a=38.5deg+-5deg b=37deg+-5deg
0000000901

(1)Pump vertical direction
(2)Coupling's key groove position at No 1 cylinder's beginning of injection
(3)-
(4)-
----------
----------
a=(10deg)
----------
----------
a=(10deg)
Stop lever angle

(PWM) Pulse width modulation (%)
(R) Rack position (mm)
Rack sensor output characteristics
1. Rack limit adjustment
(1)Measure the rack position R2 for PWM a2%.
(2)Confirm that it is within the range R2 = 15+-1 mm.
(3)Measure the rack position R1 at PWM a %.
(4)Confirm that it is within the range R2 - R1 = 10+-0.1 mm.
2. Check the limp home operation.
(1)Move the switch box's limp home switch to the limp home side.
(2)Confirm rack position L1 (mm ) and L2 (mm) for PWM in the above table.
3. Check the pull down operation.
(1)Confirm that the rack position is 19 mm at PWM B%.
(2)In the conditions described in the above table, move the switch box's pull down switch to the pull down side and confirm that the rack position momentarily becomes 1 mm or less.
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5% B=95%
----------
----------
a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5% B=95%
----------
Information:
Oils that have more than 1% total sulfated ash should not be used in aftertreatment device equipped engines.In order to achieve expected ash service intervals, performance, and life, aftertreatment device equipped diesel engines require the use of Cat DEO-ULS or oils meeting the Cat ECF-3 specification and the API CJ-4 oil category. Use of oils with more than 1% total sulfated ash in aftertreatment device equipped engines will cause the need for more frequent ash service intervals, and/or cause loss of performance. Refer to your engine specific Operation and Maintenance Manual, and refer to your aftertreatment device documentation for additional guidance.
API category oils that have not met the requirements of at least one Cat ECF specification may cause reduced engine life.
In selecting oil for any engine application, both the oil viscosity and oil performance category/specification as specified by the engine manufacturer must be defined and satisfied. Using only one of these parameters will not sufficiently define oil for an engine application.
In order to make the proper diesel engine oil viscosity grade choice, refer to the applicable “Lubricant Viscosities for Ambient Temperatures” table in this Special Publication.
Failure to follow these oil recommendations can cause shortened engine service life due to deposits and/or excessive wear.
Total Base Number (TBN) and Fuel Sulfur Levels for Direct Injection (DI) Diesel Engines
The minimum required Total Base Number (TBN) for oil depends on the fuel sulfur level. The TBN for new oil is typically determined by the "ASTM D2896" procedure. For direct injection engines that use distillate fuel, the following guidelines apply.
Table 3
TBN recommendations for applications in Cat engines
Fuel Sulfur Level percent (ppm) Cat Engine Oils TBN of Commercial Engine Oils
≤0.05 percent (≤500 ppm) Cat DEO-ULS, Cat DEO Min 7
0. 1 - 0.05 percent (1000-500 ppm) Cat DEO-ULS, Cat DEO Min 7
Above 0.1 percent (above 1000 ppm) Cat DEO Min 10 Reaching one half of new oil TBN is one of the condemning factors for diesel engine oil. In order to help provide the best protection for your engine, Cat S O S Services oil analysis is the preferred method for determining oil life. TBN of the oil is typically measured using "ASTM D2896" and/or the "ASTM D4739" test methods. It is recommended to change the oil when one half of new oil TBN with either method is reached.For example, new oil with a TBN of 10 by "ASTM D2896" should be changed when, during use, the TBN deteriorates to 5 as determined by the "ASTM D2896" test method. New oil with a TBN of 10 by "ASTM D4739" should be changed when, during use, the TBN deteriorates to 5 as determined by the "ASTM D4739" test method.Note: TBN is also commonly referred to as Base Number (BN).Excessive piston deposits can be produced by oil with a high TBN and/or high ash. These deposits can lead to a loss of control of the oil consumption and to the polishing of the cylinder bore.The use of Cat S O S Services oil analysis helps the environmental