108821-0090 ZEXEL 9 400 619 232 BOSCH INJECTION-PUMP ASSEMBLY 9400619232 1088210090 1680197608

Information Cross number Calibration Data Calibration Data Ex

Information injection-pump assembly

BOSCH 9 400 619 232 9400619232

ZEXEL 108821-0090 1088210090

NISSAN-DIESEL 1680197608 1680197608

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Cross reference number

BOSCH 9 400 619 232 9400619232

ZEXEL 108821-0090 1088210090

NISSAN-DIESEL 1680197608 1680197608

Zexel num

Bosch num

Firm num

Name

108821-0090

9 400 619 232

1680197608 NISSAN-DIESEL

INJECTION-PUMP ASSEMBLY
RG8 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=20deg+-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:

2. Locate wire 405-GY on the main cab harness near the connector exiting the cab wall on the right hand side, as shown by arrow.Cut this wire close to the connector. Splice it and the wire just assembled using an 8S4626 Splice. Be sure to splice to the portion of the wire that goes into the cab harness.3. Connect the 7N9738 Housing to the two pin connector on the 8X9862 Harness Assembly (housing containing 405-GY). Clip with a 3T3048 Clip Assembly.Installation of Ether (Chassis) Wiring Harness
The ether chassis harness for MPPS is different than the one called out in the AEIS Special Instruction.* Substitute 8X8468 Harness Assembly for 8X7653 Harness Assembly on the 785 Trucks.* Substitute 8X8467 Harness Assembly for 8X7652 Harness Assembly on the 789 Trucks.Follow the installation procedure outlined in the AEIS Special Instruction for the Ether Chassis Harness Assembly. Be sure to use the 8X8466 Wire Assembly for the 785 Trucks or the 8X8429 Wire Assembly for the 789 Trucks. This is the new harness code plug required with MPPS.Installation of 8X8469 Ether (Engine) Wiring Harness
The 8X7106 Engine Harness on the AEIS is replaced with 8X8469 Harness Assembly.Follow the installation procedure outlined in the AEIS Special Instruction for the 8X7106 Harness Assembly. In addition, the following steps need to be performed. 1. Route the end of the harness with the 8T8732 Receptacle to the 3E3530 Electronic Control Group (oil pressure sensor) installed at the right rear of the engine as shown.2. Connect the three pin receptacle to the connector on the 3E3530 Electronic Control Group (2) and clip into the 9X3495 Clip Assembly (7) installed earlier. Use 3S2093 Straps (8) to loosely secure the harness to the top rear of the engine as shown.3. Remove the 8W3048 Harness Assembly that is connected to the remaining 6T7663 Oil Pressure Switch (9) and was connected to the 6T7663 Oil Pressure Switch (9) that was removed.4. Connect an 8X8337 Harness Assembly (10) to the one remaining oil pressure switch and reconnect to the engine harness. Clip with the existing clip. DO NOT tighten the straps or clips until all new wiring harnesses have been installed so any repositioning or adjustments can be made as necessary.Checking the Automatic Ether Injection System
* The system check-out will be same as for the AEIS with the following change: "A5" harness code on the 785 (indicates 3512 application) or "A6" harness code on the 789 (indicates 3516 application) for two seconds.Retrofit to an Existing AEIS System
Necessary Parts
Installation of 3E3778 Ether Control Group
The 3E3778 Control Group is required for the MPPS System.Check the electronic control box installed with the AEIS to see if it is a 3E3778 or a 9X5303 Control Group. If a 9X5303 control Group is installed, replace it with 3E3778 Control Group and 3E3779 Film.Follow the "Installation of 9X5303 Ether Control Group" instructions outlined in the AEIS installation Special Instruction, SEHS9293. Be sure to install the 8X8398 Wire Assembly between the control and mounting plate. If an MPPS identification film is