108821-0070 ZEXEL 9 400 619 230 BOSCH INJECTION-PUMP ASSEMBLY 9400619230 1088210070 1680197606

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 230 9400619230

ZEXEL 108821-0070 1088210070

NISSAN-DIESEL 1680197606 1680197606

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Cross reference number

BOSCH 9 400 619 230 9400619230

ZEXEL 108821-0070 1088210070

NISSAN-DIESEL 1680197606 1680197606

Zexel num

Bosch num

Firm num

Name

108821-0070

9 400 619 230

1680197606 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RH8F 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. 41

Direction of rotation (viewed from drive side)
Right R

Injection timing adjustment

Direction of rotation (viewed from drive side)
Right R

Injection order 1-8-7-5- 4-3-6-2

Pre-stroke mm 6.4 6.37 6.43

Beginning of injection position
Governor side NO.1

Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25

Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25

Difference between angles 3
Cal 1-5 deg. 135 134.75 135.25

Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25

Difference between angles 5
Cal 1-3 deg. 225 224.75 225.25

Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25

Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25

Injection quantity adjustment

Rack position (12.2)

PWM % 56.8

Pump speed r/min 600 600 600

Average injection quantity mm3/st. 131 129 133

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 (7.6)

PWM % 30.9+-2. 8

Pump speed r/min 295 295 295

Average injection quantity mm3/st. 16.5 14.5 18.5

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 750--

Advance angle deg. 0 0 0

Remarks
Start

Governor adjustment_02

Pump speed r/min 700

Advance angle deg. 0.5

Governor adjustment_03

Pump speed r/min 1000

Advance angle deg. 3 2.5 3.5

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
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aa=20mm bb=1mm
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a=27deg+-5deg b=37deg+-5deg

0000000901

(1)Pump vertical direction (2)Position of the coupling's key groove at the beginning of injection of the No. 8 cylinder. (3)Pre-stroke: aa (4)-
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aa=6.4+-0.03mm
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a=(80deg)

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:

Installation of Nozzles, Ether Supply Tubes and Connectors
1. If the machine does not already have an ether aid starting system, remove the plugs from turbocharger outlet adapters on the engine. 2. Install a 3B6768 Bushing with a 7X1078 Nozzle Assembly (2) where each plug was removed. If machine was equipped with an ether aid starting system. Discard old nozzles and install new nozzles.3. When installing each nozzle assembly (2), the indicator mark at location (J) must be at the top as shown. Tighten the nozzle to a torque of 2.8 N m (25 lb in).
Top View
Side View DO NOT overtighten tube assembly fittings. Over tightening can cause damage to tubing.4. Install 8X0912 Tube (9) in the front nozzle and 8W8174 Tube (7) in the rear nozzle as shown. Connect tubes (7) and (9) to 8C9006 Tee (8) using two 5P6314 Sleeves and 5P6313 Nuts.5. Put 8W8172 Tube (5) in position along the cylinder block and connect it to 8C9006 Tee (8) as shown using 5P6314 Sleeve and 5P6313 Nut.6. Connect one end of 8W8171 Tube (10) to elbow (11) on the bottom of the shuttle valve using a 5P6313 Nut and 5P6314 Sleeve. Fasten the tube to the frame cross tube using 6V2686 Clip (6) as shown.7. Connect one end of 7N0140 Tube Assembly (4) to the end of 8W8171 Tube (10) and connect the other end to the free end of 8W8172 Tube (5).8. Fasten the ether tubing assemblies, using three 6V2686 Clips (3) with existing bolts, on engine block and right regulator housing as shown.Installation of Ether Cylinders
1. Turn the disconnect switch to the ON position and put the start switch key in the OFF position. Make sure the two lamps on the console and the two yellow LEDs on the ECU are flashing.If they are flashing, it indicates that the control is functioning and recognizes that no ether cylinders are installed.2. Inspect the two digit, seven segment LED display on the ECU. It must read "OO". This in an indication that there are no faults.If the display does not read "OO", refer to the Service Manual for a troubleshooting procedure of the system. 3. Remove protective caps (1) and (3) from 9X7137 Ether Solenoid Valves (2) and (4). Install a new 9X7138 Filter Assembly in each solenoid valve inlet.4. Install a 9X0147 Collar on the neck of each new 7X1062 Ether Cylinder.5. Remove the protective plug from the end of the new FULL ether cylinder, then install the new ether cylinder on ether solenoid valve (2). The ether valve assembly at left location (C) is referred to as Ether Assembly No. 1. The ether valve assembly at right location (D) is referred to as Ether Assembly No. 2.Make sure that the dash mounted ETHER OUT warning lamp No. 1 and the ETHER OUT warning LED on the ECU are OFF. Repeat this procedure for installation of