Information injection-pump assembly
BOSCH
9 400 611 291
9400611291
ZEXEL
107492-0130
1074920130
NISSAN-DIESEL
1670031D03
1670031d03
Rating:
Service parts 107492-0130 INJECTION-PUMP ASSEMBLY:
1.
_
5.
AUTOM. ADVANCE MECHANIS
6.
COUPLING PLATE
9.
_
11.
Nozzle and Holder
16600-31D03
12.
Open Pre:MPa(Kqf/cm2)
19.6{200}
15.
NOZZLE SET
Include in #1:
107492-0130
as INJECTION-PUMP ASSEMBLY
Cross reference number
BOSCH
9 400 611 291
9400611291
ZEXEL
107492-0130
1074920130
NISSAN-DIESEL
1670031D03
1670031d03
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
105780-8250
Bosch type code
1 688 901 101
Nozzle
105780-0120
Bosch type code
1 688 901 990
Nozzle holder
105780-2190
Opening pressure
MPa
20.7
Opening pressure
kgf/cm2
211
Injection pipe
Outer diameter - inner diameter - length (mm) mm 8-3-600
Outer diameter - inner diameter - length (mm) mm 8-3-600
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
2.5
2.5
2.5
RED4 control unit part number
407915-0
590
RED4 rack sensor specifications
mm
19
PS/ACT control unit part no.
407980-2
24*
Digi switch no.
03
Direction of rotation (viewed from drive side)
Right R
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
Right R
Injection order
1-3-4-2
Pre-stroke
mm
5.1
5.07
5.13
Beginning of injection position
Drive side NO.1
Drive side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.75 90.25
Cal 1-3 deg. 90 89.75 90.25
Difference between angles 2
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 3
Cyl.1-2 deg. 270 269.75 270.25
Cyl.1-2 deg. 270 269.75 270.25
Injection quantity adjustment
Rack position
(13.6)
PWM
%
64.9
Pump speed
r/min
900
900
900
Average injection quantity
mm3/st.
106
105
107
Max. variation between cylinders
%
0
-4
4
Basic
*
PS407980-224*
V
2.25+-0.
01
PS407980-224*
mm
3.1+-0.0
5
Injection quantity adjustment_02
Rack position
(7.5)
PWM
%
30.1+-2.
8
Pump speed
r/min
495
495
495
Average injection quantity
mm3/st.
12.4
10.6
14.2
Max. variation between cylinders
%
0
-10
10
PS407980-224*
V
V1+0.05+
-0.01
PS407980-224*
mm
5+-0.03
Remarks
Refer to items regarding the pre-stroke actuator
Refer to items regarding the pre-stroke actuator
0000001201
CU407980-224*
*
Actuator retarding type
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
2
1.95
2.05
Output voltage
V
2.83
2.82
2.84
Adjustment
*
_02
CU407980-224*
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Pre-stroke
mm
5.1
5.07
5.13
Output voltage
V
1.2
1
1.4
Confirmation
*
Remarks
Output voltage V1
Output voltage V1
_03
CU407980-224*
*
Supply voltage
V
24
23.5
24.5
Ambient temperature
degC
23
18
28
Output voltage
V
3.05
3.05
Confirmation of operating range
*
Test data Ex:
Speed control lever angle
N:Pump normal
S:Stop the pump.
(1)Rack position = aa
(2)Rack position bb
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
a=27deg+-5deg b=37deg+-5deg
0000000901
(1)Pump vertical direction
(2)Position of coupling's standard threaded hole at No 1 cylinder's beginning of injection
(3)B.T.D.C.: aa
(4)Pre-stroke: bb
----------
aa=3deg bb=5.1+-0.03mm
----------
a=(50deg)
----------
aa=3deg bb=5.1+-0.03mm
----------
a=(50deg)
Stop lever angle
(1)Pointer
(2)Injection timing aligning mark
(3)Fly weight
(4)The actual shape and direction may be different from this illustration.
Operation sequence
1. Turn the prestroke actuator OFF.
2. Turn the camshaft as far as the No.1 cylinder's beginning of injection position.
3. Check that the pointer alignment mark of the injection pump and the alignment mark of the flywheel are matching.
4. If they are not matching, erase the alignment mark on the flywheel side, and stamp an alignment mark on the flywheel position that matches with the pointer side alignment mark.
5. Check again that the coupling's key groove position is in the No.1 cylinder's beginning of injection position.
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----------
----------
----------
0000001301
A : Stopper pin
B: Connector
----------
----------
----------
----------
0000001401
C:Shim
----------
----------
----------
----------
0000001501
A:Sealing position
B:Pre-stroke actuator
1. When installing the pre-stroke actuator on the pump, first tighten the installation bolts loosely, then move the actuator fully counterclockwise (viewed from the drive side).
Temporary tightening torque: 1 - 1.5 N.m (0.1 - 0.15 kgf.m)
2. Move the actuator in the clockwise direction when viewed from the drive side, and adjust so that it becomes the adjustment point of the adjustment value. Then tighten it.
Tightening torque: 7^9 N.m (0.7^0.9 kgf.m)
3. After prestroke actuator installation adjustment, simultaneously stamp both the actuator side and housing side.
----------
----------
----------
----------
0000001701
(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:
Introduction
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Some of the 3408E engines and 3412E engines in the above listed machines may experience hard starting or low power due to oil that is leaking past the poppet valve in the injector. The oil leakage is caused by the operating conditions at either low idle or high idle. Excessive oil leakage can reduce actuation pressure to the fuel injector. This may prevent fuel injection.Solution
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Follow the proper troubleshooting procedure for the correct engine. If the problem is not located and the symptoms that are listed above continue, remove the engine valve covers. Electrically disable the injectors. Crank the engine. Watch the spill ports of the injector for oil leakage. A small amount of oil leakage is acceptable. A continuous stream of oil may mean leakage from the poppet valve. Excessive leakage from the poppet valve may prevent fuel injection.Note: Normal oil pressure during cranking should be 5 MPa (725 psi). Oil pressure below 5 MPa (725 psi) may indicate excessive oil leakage in injectors. Do not replace the oil pump. Service personnel should replace the injectors that have a continuous flow of oil from the oil ports. Injectors that have a continuous flow of oil and injectors that are within the guidelines of warranty can be returned. Injectors that do not have a continuous flow of oil should not be replaced. Injectors that do not have a continuous flow of oil should not be returned.Note: For additional information on the operation of Hydraulic Electronic Unit Injectors HEUI, refer to CD, RENR1390.
Illustration 1 g01308874
(1) Oil drain portThe oil drain ports are located underneath the solenoid. This will direct the oil flow downward. Some oil may also leak from the rectangular slots at the side of the solenoid. Excess oil leakage will still be visible on the cylinder head.
The problem that is identified below does not have a known permanent solution. Until a permanent solution is known, use the solution that is identified below.Problem
Some of the 3408E engines and 3412E engines in the above listed machines may experience hard starting or low power due to oil that is leaking past the poppet valve in the injector. The oil leakage is caused by the operating conditions at either low idle or high idle. Excessive oil leakage can reduce actuation pressure to the fuel injector. This may prevent fuel injection.Solution
Electrical shock hazard. The electronic unit injector system uses 90-120 volts.
Follow the proper troubleshooting procedure for the correct engine. If the problem is not located and the symptoms that are listed above continue, remove the engine valve covers. Electrically disable the injectors. Crank the engine. Watch the spill ports of the injector for oil leakage. A small amount of oil leakage is acceptable. A continuous stream of oil may mean leakage from the poppet valve. Excessive leakage from the poppet valve may prevent fuel injection.Note: Normal oil pressure during cranking should be 5 MPa (725 psi). Oil pressure below 5 MPa (725 psi) may indicate excessive oil leakage in injectors. Do not replace the oil pump. Service personnel should replace the injectors that have a continuous flow of oil from the oil ports. Injectors that have a continuous flow of oil and injectors that are within the guidelines of warranty can be returned. Injectors that do not have a continuous flow of oil should not be replaced. Injectors that do not have a continuous flow of oil should not be returned.Note: For additional information on the operation of Hydraulic Electronic Unit Injectors HEUI, refer to CD, RENR1390.
Illustration 1 g01308874
(1) Oil drain portThe oil drain ports are located underneath the solenoid. This will direct the oil flow downward. Some oil may also leak from the rectangular slots at the side of the solenoid. Excess oil leakage will still be visible on the cylinder head.