108621-0012 ZEXEL INJECTION-PUMP ASSEMBLY Calibration Data 1086210012 1680196674

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

ZEXEL 108621-0012 1086210012

NISSAN-DIESEL 1680196674 1680196674

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Cross reference number

ZEXEL 108621-0012 1086210012

NISSAN-DIESEL 1680196674 1680196674

Zexel num

Bosch num

Firm num

Name

108621-0012
108621-0013

1680196674 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PF6TB * K

Calibration Data:

Adjustment conditions

Test oil
1404 Test oil ISO4113 or {SAEJ967d}

Test oil temperature degC 40 40 45

Nozzle and nozzle holder 105780-8250

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

RED3 control unit part number 407910-3 960

RED3 rack sensor specifications mm 19

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

Digi switch no. 31

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 6.4 6.37 6.43

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 (15.2)

Vist V 1.57 1.57 1.57

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 166.5 164.5 168.5

Max. variation between cylinders % 0 -4 4

Basic *

PS407980-224* V 2.45+-0. 01

PS407980-224* mm 4+-0.05

Injection quantity adjustment_02

Rack position (8.7)

Vist V 2.5 2.4 2.6

Pump speed r/min 270 270 270

Average injection quantity mm3/st. 15.8 14.8 16.8

Max. variation between cylinders % 0 -10 10

PS407980-224* V V1+0.05+ -0.01

PS407980-224* mm 6.3+-0.0 3

Remarks
Refer to items regarding the pre-stroke actuator

Governor adjustment

Pump speed r/min 775--

Advance angle deg. 0 0 0

Remarks
At Q = actual measurement (mm3/st) / N=690 (r/min),start of advance

Governor adjustment_02

Pump speed r/min 725

Advance angle deg. 0.3

Remarks
Q = actual measurement (mm3/st) / N=690 (r/min)

Governor adjustment_03

Pump speed r/min 1000

Advance angle deg. 2.5 2.2 2.8

Remarks
Q = actual measurement (mm3/st) / N=1050 (r/min),end of advance

0000001201

Pre-stroke mm 6.4 6.37 6.43

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 8.5 8 9

Remarks
When the eccentric pin is tightened

_03

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 4 3.95 4.05

Output voltage V 2.45 2.44 2.46

Adjustment *

_04

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 6.4 6.37 6.43

Output voltage V 1.2 1 1.4

Confirmation *

Remarks
Output voltage V1

_05

Supply voltage V 24 23.5 24.5

Ambient temperature degC 23 18 28

Pre-stroke mm 3.4

Output voltage V 3 2.98 3

Confirmation *

_06

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=20mm bb=1mm
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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=6.4+-0.03mm
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a=(30deg)

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

(Rs) rack sensor specifications (C/U) control unit part number (V) Rack sensor output voltage (R) Rack position (mm) 1. Confirming governor output characteristics (rack 19 mm, span 6 mm) (1)When the output voltages of the rack sensor are V1 and V2, check that the rack positions R1 and R2 in the table above are satisfied.
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Information:

Heavy fuel oil, residual fuel, or blended fuel can be used only in Cat 3600 Series engines that are configured to use heavy fuel oil.DO NOT use these types of fuel in diesel engines that are configured to use distillate diesel fuel. Do not use these types of fuel in engines that are Tier 4 EPA certified. Failure to follow this recommendation will result in severe wear of components and engine failure.
Gas Oil - A light distillate fuel which does not contain residual fuel. Gas oil is approximately ASTM No.1 diesel fuel.Marine Diesel - A distillate fuel that boils at a higher temperature than gas oil. This fuel varies from ASTM No.2 to ASTM No.4. The composition can vary within the following range: ASTM No.2 diesel fuel, No.2 that is contaminated with heavier fuel in the bottom of a tanker and No.2 that is blended with as much as 20 percent of residual fuel.
Do NOT use fuel that is blended with residual fuel in diesel engines that are configured to use distillate fuel. Severe component wear and component failures will result if this type of fuel is used in diesel engines that are configured to use distillate fuel.
Table 1 lists some permissible marine diesel fuels.Blended Fuel Oil - A blend of distillate and residual fuel. This fuel is blended to the viscosity that is requested by the operator or the manufacturer of the engine. Blended fuel is also referred to as heavy fuel oil (HFO).Note: Do NOT use blended fuel in Cat diesel engines that are configured to use distillate fuel. Severe component wear and component failures will result if this type of fuel is used in diesel engines that are configured to use distillate fuel.Residual Fuel - A residue from the distillation of crude oil in a refinery. Residual fuel is also referred to as heavy fuel oil (HFO).Note: DO NOT use residual fuel in Cat diesel engines that are configured to use distillate fuel. Severe component wear and component failures will result if this type of fuel is used in diesel engines that are configured to use distillate fuel.DO NOT use fuels that are classified as CIMAC DC or ISO 8217F-DMC.The use of fuels that are classified as CIMAC DC or ISO 8217F-DMC can reduce the service life of components.Only use fuels that meet or exceed Cat recommendations. The use of fuels that are not recommended can reduce the service life of components.The classifications that are listed in Table 1 are established by the International Standards Organization (ISO). Fuels which meet the classifications that are listed in Table 1 are permissible for use in Cat 3600 Series diesel engines that are configured to use distillate fuel. Fuels classified by the Council International Des Machines a Combustion (CIMAC) that are equivalent to the ISO Classifications indicted in Table 1 are also permissible for use in Cat 3600 and C280 Series engines.
Table 1
Marine Distillate Diesel Fuels That Are Permissible for Use In Caterpillar 3600 Series and C280 Series