107691-0155 ZEXEL 9 400 611 354 BOSCH INJECTION-PUMP ASSEMBLY 9400611354 1076910155 16801z5608

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 611 354 9400611354

ZEXEL 107691-0155 1076910155

NISSAN-DIESEL 16801Z5608 16801z5608

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Buy INJECTION-PUMP ASSEMBLY 107691-0155 zexel genuine, new aftermarket engine parts with delivery

Service parts 107691-0155 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 107069-1460

3. GOVERNOR 105961-0071

4. SUPPLY PUMP 105237-5460

5. AUTOM. ADVANCE MECHANIS 105681-2600

6. COUPLING PLATE 105664-2530

7. COUPLING PLATE

8. _ 159645-2020

9. _

10. NOZZLE AND HOLDER ASSY 105118-7850

11. Nozzle and Holder 16600-Z5714

12. Open Pre:MPa(Kqf/cm2) 16.7{170}/19.6{200}

13. NOZZLE-HOLDER 105048-4360

14. NOZZLE

15. NOZZLE SET 105019-1720

Include in #1:

107691-0155 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 611 354 9400611354

ZEXEL 107691-0155 1076910155

NISSAN-DIESEL 16801Z5608 16801z5608

Zexel num

Bosch num

Firm num

Name

107691-0155

9 400 611 354

16801Z5608 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
FE6TB K 14CG INJECTION PUMP ASSY TICS MD-TI6 TICS

Calibration Data:

Adjustment conditions

Test oil
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

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

PS/ACT control unit part no. 407980-2 24*

Digi switch no. 14

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-4-2-6- 3-5

Pre-stroke mm 5.1 5.07 5.13

Beginning of injection position
Drive side NO.1

Difference between angles 1
Cal 1-4 deg. 60 59.75 60.25

Difference between angles 2
Cyl.1-2 deg. 120 119.75 120.25

Difference between angles 3
Cal 1-6 deg. 180 179.75 180.25

Difference between angles 4
Cal 1-3 deg. 240 239.75 240.25

Difference between angles 5
Cal 1-5 deg. 300 299.75 300.25

Injection quantity adjustment

Rack position (11.3)

PWM % 51.5

Pump speed r/min 700 700 700

Average injection quantity mm3/st. 108 107 109

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 (6.7)

PWM % 25.6+-2. 8

Pump speed r/min 445 445 445

Average injection quantity mm3/st. 11 9.2 12.8

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

Governor adjustment

Pump speed r/min 1150--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 1100

Advance angle deg. 0.3

Governor adjustment_03

Pump speed r/min 1300

Advance angle deg. 4 3.7 4.3

Remarks
Finish

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

_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
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aa=1mm bb=20mm
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a=20deg+-5deg b=37deg+-5deg

0000000901

(1)Pump vertical direction (2)Coupling's key groove position at No 1 cylinder's beginning of injection (3)Pre-stroke: aa (4)-
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aa=5.1+-0.03mm
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a=(20deg)

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
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0000001401

C:Shim
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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.
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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.
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a1=16.25% a2=72.5% L1=1--mm L2=19++mm A=5 % B=95%
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Information:

Image1.1.2
2. Remove existing 215-2705 cap (Image 1.2.1), and replace with new 272-7102 cap, utilizing the existing cap screws (Image 1.2.1). Insure that threads are coated with Thread Lock P/N 9S-3263 or 4C-4030 and torque cap screws to 7(+/-1) Nm.
Image1.2.1
3. Install new 263-2905 switches (Image 1.3.1) into caps insuring that threads are coated with P/N 4C-5598 High temperature Anti-Seize and torque to 16(+/-2) Nm
Image1.3.1
4. Connect new switch to the applicable wiring harness. Install ladder clips as shown (Image 1.4.1), using 0S-1588 Bolts coated with P/N 4C-5598 High Temperature Anti-Seize to replace the top two existing bolts as shown. Torque these bolts to 47 (+/-9) Nm.
Image1.4.1
Image1.4.2
5. IMPORTANT - Tie-wrap new switch wiring to existing solenoid wiring as shown (Images 1.4.1 & 1.4.2), to prevent thermal damage to wiring.
6. Install information films P/N 179-0133 on electrically actuated Air Shut Offs over the existing films on the solenoids as shown in (Image 1.6.1) or install information films for hydraulically actuated Air Shut Offs over the existing films on the valve covers as shown in (Image 1.6.2).
Films in languages other than English are available under the following part numbers:
-Arabic 297-2613
-French 297-2614
-German 297-2615
-Spanish 297-2616
-Portuguese 297-2617
-Russian 297-2618
Image1.6.1
Image1.6.2
Important Notes:
1. If a new switch is to be painted, mask the vent holes around the perimeter of the switch before painting and be sure to remove the masking after the paint dries.
2. Test completed modifications as detailed below for the specific ECM installed on the engine (ADEM 2 or ADEM 3).
OPERATIONAL TEST - ADEM 2 Engine Control Modules ONLY
Note: (For Troubleshooting purposes) The ASO switches are normally closed switches that are in the closed state when the air shutoff valves are latched in the open ("Run") position. If the air shutoff valves are in the closed ("Stop") position, the switch will be in the open state, causing an emergency stop and shutting the engine down. This also prevents the engine from starting.
DO NOT START THE ENGINE! Ensure that the engine control is in the "OFF" position.
1. Ensure that both air shutoff gates are latched in the OPEN position and ensure that both air shutoff switches are connected. Turn on the power to the engine control panel. Both air shutoff gates should remain open. If both air shutoff gates do not remain open, check the wiring for the air shutoff switches.
2. With the power for the engine control panel in the ON position, activate the "EMERGENCY STOP" switch. Both of the air shutoff gates should close. If both air shutoff gates close, proceed to step 3. If both air shutoff gates do not close, check the wiring for the air shutoff switches and check the wiring for the solenoids. Activate the "EMERGENCY STOP" switch again. When both air shutoff gates close, proceed to step 3.
3. Turn the power to the engine control panel to the OFF position. Ensure that the "EMERGENCY STOP" switch is in the RUN position. Latch only the right side air shutoff gate to the OPEN position. Turn the power for the engine control panel to