108621-0060 ZEXEL 9 400 612 014 BOSCH INJECTION-PUMP ASSEMBLY 9400612014 1086210060 1680196800

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 612 014 9400612014

ZEXEL 108621-0060 1086210060

NISSAN-DIESEL 1680196800 1680196800

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Service parts 108621-0060 INJECTION-PUMP ASSEMBLY:

1. _

2. FUEL INJECTION PUMP 108062-3990

3. GOVERNOR 105960-0130

4. SUPPLY PUMP 105237-4220

5. AUTOM. ADVANCE MECHANIS 105684-0120

6. COUPLING PLATE 105664-2540

7. COUPLING PLATE

8. _ 159640-2020

9. _

10. NOZZLE AND HOLDER ASSY 105110-8100

11. Nozzle and Holder 16600-96662

12. Open Pre:MPa(Kqf/cm2) 17.7{180}/20.6{210}

13. NOZZLE-HOLDER 105041-4310

14. NOZZLE

15. NOZZLE SET 105019-2650

Include in #1:

108621-0060 as INJECTION-PUMP ASSEMBLY

Cross reference number

BOSCH 9 400 612 014 9400612014

ZEXEL 108621-0060 1086210060

NISSAN-DIESEL 1680196800 1680196800

Zexel num

Bosch num

Firm num

Name

108621-0060
108621-0070

9 400 612 014

1680196800 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
PF6HTA * 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

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. 33

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 (16.4)

PWM % 80.1

Pump speed r/min 650 650 650

Average injection quantity mm3/st. 228 226 230

Max. variation between cylinders % 0 -4 4

Basic *

PS407980-224* V 2.2+-0.0 1

PS407980-224* mm 4+-0.05

Injection quantity adjustment_02

Rack position (7.4)

PWM % 29.5+-2. 8

Pump speed r/min 330 330 330

Average injection quantity mm3/st. 16.5 15.5 17.5

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 920--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 870

Advance angle deg. 0.5

Governor adjustment_03

Pump speed r/min 980

Advance angle deg. 1.5 1 2

Remarks
Finish

0000001201

Pre-stroke mm 6.4 6.37 6.43

Remarks
When the timing sleeve is pushed up

_02

Connector angle deg. 11.5 11 12

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 2.4 2.35 2.45

Output voltage V 2.95 2.94 2.96

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

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=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)-
----------
aa=6.4+-0.03mm
----------
a=(25deg)

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%
----------

Information:

Introduction
The Environmental Protection Agency (EPA) has mandated that a DEF quality sensor must be installed on certain engines built after 2016. This new DEF quality sensor is integrated into the DEF header inside the DEF tank. The new style DEF header utilizes CAN C communication, so the wiring to the DEF header has been slightly modified on product going forward. However, the Dosing Control Unit (DCU) remains compatible to both setups with the latest engine software. ( 507-7605 Engine Software (24V DCU) or 507-7546 Engine Software (12V DCU)). As part of the DEF quality sensor implementation, a new configuration parameter setting is used on the engine Electronic Control Module (ECM) in Cat ET to identify whether a DEF quality sensor is"installed" or "not installed". Below are some different diagnostic codes for incompatible hardware and configuration setting as well as different service scenarios that may be encountered with this change and how to resolve any issues in these particular service scenarios. In addition to this Special Instruction, there is a video detailing these changes posted on Cat Channel 1.Diagnostic Codes When Parts/Settings Are Not Compatible
DEF quality header not installed but configuration set to "installed".
Table 1
J1939 Code and Description CDL Code and Description
1235-9
J1939 Network #3 : Abnormal Update Rate 5856-9
J1939 Network #3 : Abnormal Update Rate DEF quality header installed but configuration set to not installed.
Table 2
J1939 Code and Description CDL Code and Description
1761-3
Aftertreatment 1 Diesel Exhaust Fluid Tank Level : Voltage Above Normal 3130-3
Aftertreatment #1 SCR Catalyst Reagent Tank #1 Level Sensor : Voltage Above Normal
3031-3
Aftertreatment 1 Diesel Exhaust Fluid Tank Temperature : Voltage Above Normal 3134-3
Aftertreatment #1 SCR Catalyst Reagent Tank #1 Temperature Sensor : Voltage Above Normal DEF Quality Sensor Service Scenarios
Replacement Industrial Engine (2016 and earlier builds)
Replace with new engine (old engine no longer serviceable). Update to DEF quality sensor by installing a new DEF header, wiring harness, and DCU software and changing DEF quality sensor configuration status to "installed" in Cat ET.Replacement Machine Engine (2016 and Earlier Builds)
Replace with older service replacement Engine Arrangement Complete (EAC) engine (no other changes needed, confirm that DEF quality sensor configuration is set to "not installed" in CAT ET).
If dealer orders new EAC, update to DEF quality sensor is required (below scenario).Replacement Engine (2017and Future Builds)
Replace with latest EAC engine.Install DEF Quality Sensor on 2016 or Earlier Builds
Requires DCU software update, Pump, Electronic, and Tank Unit (PETU) wiring harness update, change DEF quality sensor configuration status to"installed".Replace DCU
No effect - new DCU hardware and software is compatible to both DEF headers.Replace Engine ECM
No effect when using ECM replacement file.
If engine ECM is replaced without the ECM replacement file, the DEF quality sensor configuration setting will default to "not installed" and may need to be updated if machine utilizes DEF quality sensor (requires Factory Passwords to change).Replace Wiring Harness
No effect - both new and old harness part numbers are available. Order same part number that is removed.