Information injection-pump assembly
BOSCH
9 400 619 231
9400619231
ZEXEL
108821-0080
1088210080
NISSAN-DIESEL
1680197607
1680197607
Rating:
Cross reference number
BOSCH
9 400 619 231
9400619231
ZEXEL
108821-0080
1088210080
NISSAN-DIESEL
1680197607
1680197607
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
2.6
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
Right R
Injection timing adjustment
Direction of rotation (viewed from drive side)
Right R
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
Governor side NO.1
Difference between angles 1
Cal 1-8 deg. 45 44.75 45.25
Cal 1-8 deg. 45 44.75 45.25
Difference between angles 2
Cal 1-7 deg. 90 89.75 90.25
Cal 1-7 deg. 90 89.75 90.25
Difference between angles 3
Cal 1-5 deg. 135 134.75 135.25
Cal 1-5 deg. 135 134.75 135.25
Difference between angles 4
Cal 1-4 deg. 180 179.75 180.25
Cal 1-4 deg. 180 179.75 180.25
Difference between angles 5
Cal 1-3 deg. 225 224.75 225.25
Cal 1-3 deg. 225 224.75 225.25
Difference between angles 6
Cal 1-6 deg. 270 269.75 270.25
Cal 1-6 deg. 270 269.75 270.25
Difference between angles 7
Cyl.1-2 deg. 315 314.75 315.25
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
Refer to items regarding the pre-stroke actuator
Governor adjustment
Pump speed
r/min
750--
Advance angle
deg.
0
0
0
Remarks
Start
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
Finish
0000001201
Pre-stroke
mm
6.4
6.37
6.43
Remarks
When the timing sleeve is pushed up
When the timing sleeve is pushed up
_02
Connector angle
deg.
11.5
11
12
Remarks
When the eccentric pin is tightened
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
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=27deg+-5deg b=37deg+-5deg
----------
aa=20mm bb=1mm
----------
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)-
----------
aa=6.4+-0.03mm
----------
a=(80deg)
----------
aa=6.4+-0.03mm
----------
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.
----------
----------
----------
----------
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:
Use of the Pickup During Wet Conditions
If the pickup becomes wet, it may operate intermittently or not at all. Although the pickup is water resistant, it is not waterproof. Water spray from rain or other sources may cause the pickup to stop producing an output signal.If this happens, the pickup should be removed from the engine and allowed to dry out thoroughly. If necessary, the pickup can be dried in an oven at approximately 50°C (122°F). After drying, the pickup should operate correctly.If it is not possible to keep the pickup dry, use the following procedure: If the pickup must be used during wet conditions, it may be possible to protect it from moisture by using a water displacing spray such as WD-40®.Remove the pickup from the engine. Thoroughly spray the pickup from all directions. Make sure the pickup is completely covered with the spray. Reinstall the pickup on the engine and check its operation.When water first contacts the pickup, the unit may stop working temporarily, but will start working again after the water has been displaced by the solution. If necessary, spray the solution on the pickup after installation on the injection line.Permanent Installation on the Engine
If the pickup is to be permanently installed on the engine, install the pickup on the fuel injection line in the usual manner. Make sure that the thumbscrew is hand tightened securely, but not over tightened. Run the engine and check the operation of the pickup.Make sure that the pickup and line are clean and dry. If the pickup is working correctly, use a can of spray paint to thoroughly paint the pickup from all directions. Several coats should be applied. Let the paint dry thoroughly before operating the engine.Checking the Operation of the Amplifier and Pickup
(1) 6V2100 Multitach. (2) 5P9698 Calibrator. (3) 5P7366 Power Cable. (4) Digital Multimeter. (5) Screwdriver. (6) 6V6152 Adapter. Screwdriver (5) should have a blade approximately 150 mm (6 in) long with 6 mm (.25 in) diameter shaft of round bare metal (not anodized or insulated).The 6V6152 Adapter (6) is a phono plug-to-BNC connector. Modifications must be made to the 5P9698 Calibrator (2). Refer to Special Instruction, SMHS7504-01.Checking the 4C6812 Amplifier
(1) 6V6152 Adapter Plug. (2) 5P9698 Calibrator. (3) 4C6812 Amplifier. (4) Connector. (5) 5P7366 Power Cable. (6) Knob. (7) Battery Indicator. (8) No Input Signal Light.1. Install 6V6152 Adapter Plug (1) on the end of the output cable on 5P9698 Calibrator (2). Plug the adapter into 4C6812 Amplifier (3).2. Check the operation of the multitach being used by performing the CHECKING PHOTO OPERATION test procedure contained in Special Instruction SEHS7807. (This is to ensure it is operating correctly on PHOTO operation.)3. Plug connector (4), on the end of the amplifier output cable, into the PH (photo) connector on the multitach. Attach 5P7366 Power Cable (5) to the multitach and to a suitable power source. Refer to SEHS7807.4. Program the multitach for .5 P/REV and to read R/MIN on the PH (photo) input. Turn knob (6) on
If the pickup becomes wet, it may operate intermittently or not at all. Although the pickup is water resistant, it is not waterproof. Water spray from rain or other sources may cause the pickup to stop producing an output signal.If this happens, the pickup should be removed from the engine and allowed to dry out thoroughly. If necessary, the pickup can be dried in an oven at approximately 50°C (122°F). After drying, the pickup should operate correctly.If it is not possible to keep the pickup dry, use the following procedure: If the pickup must be used during wet conditions, it may be possible to protect it from moisture by using a water displacing spray such as WD-40®.Remove the pickup from the engine. Thoroughly spray the pickup from all directions. Make sure the pickup is completely covered with the spray. Reinstall the pickup on the engine and check its operation.When water first contacts the pickup, the unit may stop working temporarily, but will start working again after the water has been displaced by the solution. If necessary, spray the solution on the pickup after installation on the injection line.Permanent Installation on the Engine
If the pickup is to be permanently installed on the engine, install the pickup on the fuel injection line in the usual manner. Make sure that the thumbscrew is hand tightened securely, but not over tightened. Run the engine and check the operation of the pickup.Make sure that the pickup and line are clean and dry. If the pickup is working correctly, use a can of spray paint to thoroughly paint the pickup from all directions. Several coats should be applied. Let the paint dry thoroughly before operating the engine.Checking the Operation of the Amplifier and Pickup
(1) 6V2100 Multitach. (2) 5P9698 Calibrator. (3) 5P7366 Power Cable. (4) Digital Multimeter. (5) Screwdriver. (6) 6V6152 Adapter. Screwdriver (5) should have a blade approximately 150 mm (6 in) long with 6 mm (.25 in) diameter shaft of round bare metal (not anodized or insulated).The 6V6152 Adapter (6) is a phono plug-to-BNC connector. Modifications must be made to the 5P9698 Calibrator (2). Refer to Special Instruction, SMHS7504-01.Checking the 4C6812 Amplifier
(1) 6V6152 Adapter Plug. (2) 5P9698 Calibrator. (3) 4C6812 Amplifier. (4) Connector. (5) 5P7366 Power Cable. (6) Knob. (7) Battery Indicator. (8) No Input Signal Light.1. Install 6V6152 Adapter Plug (1) on the end of the output cable on 5P9698 Calibrator (2). Plug the adapter into 4C6812 Amplifier (3).2. Check the operation of the multitach being used by performing the CHECKING PHOTO OPERATION test procedure contained in Special Instruction SEHS7807. (This is to ensure it is operating correctly on PHOTO operation.)3. Plug connector (4), on the end of the amplifier output cable, into the PH (photo) connector on the multitach. Attach 5P7366 Power Cable (5) to the multitach and to a suitable power source. Refer to SEHS7807.4. Program the multitach for .5 P/REV and to read R/MIN on the PH (photo) input. Turn knob (6) on